Design and Fabrication of a CNC

Precision Router

Senior design project report

BY

Muhammad Ismail Leghari

Muhammad Shoaib Butt
Saad Ali
Sarmad Ishfaq

Supervised by

Dr. Wasim Ahmed Khan

Faculty of Mechanical Engineering

GIK Institute of Engineering Sciences & Technology
 i

Design and Fabrication of a CNC

Precision Router

Senior design project report

January 2017

BY

Muhammad Ismail Leghari 2013248

Muhammad Shoaib Butt 2013261
Saad Ali 2013318
Sarmad Ishfaq 2013338

Supervised by

Dr. Wasim Ahmed Khan

Submitted in partial fulfillment of the requirements for the degree of

Bachelor of Science

Faculty of Mechanical Engineering

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GIK Institute of Engineering Sciences & Technology

January 2017

FACULTY OF MECHANICAL ENGINEERING

Ghulam Ishaq Khan Institute of Engineering Sciences and Technology

Senior design project report

Approved as to style and content by:

Name and
signature of Advisor(s):

FYP Coordinator (For Formatting):

Date:_____________
 iii

Abstract
Although 3D printing for Additive Manufacturing has been around in the global market
for over two decades now, the concept is still alien to most of the developing countries
until a couple of years ago when research and development started with a rapid pace. Lack
of precision and accuracy and expensive technology not available locally are the core
issues encountered by the setups working on this type of manufacturing.

Nowadays, computer numeric control (CNC) machines are used to perform almost all of
the manufacturing processes. The main focus of this paper is to measure the vibrations of
the CNC router so that it can reach a precision up to the scale of microns (10-6) to facilitate
additive manufacturing.

This objective is made achievable by designing a router with ball screws instead of
customized lead screws to get better precision and accuracy. Similarly, new motors of
required torques are selected to avoid any kind of energy wastage in the form of vibrations
or noise, increasing the precision of the CNC router. The increased precision results in the
better production of products for additive manufacturing processes by changing the
routing head to accomplish the desired additive manufacturing technique.

Future prospects of this final year project includes micron scale precision of material
removal processes using spindle motors along with some further modifications like using
material removal carbon titanium (C-Ti) graded tools in place additive manufacturing
heads.

Key words:

CNC machines, Precision Router, Additive Manufacturing, structural-steel casting

micron-scale precision, pneumatic head manufacturing, material removal processes.
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TABLE OF CONTENTS
Abstract ............................................................................................................................ iii
Nomenclature ...................................................................................................................vii
Chapter 1 INTRODUCTION ......................................................................................... 1
1.1 Motivation and Background .................................................................... 1
1.2 Problem Statement .................................................................................. 1
1.3 Scope of Work and Expected Outcomes ................................................. 2
1.4 Report Outline ......................................................................................... 2
1.5 Project Schedule ...................................................................................... 3
1.6 Individual and Team Contribution .......................................................... 3
Chapter 2 LITERATURE REVIEW .............................................................................. 4
2.1 Literature review ..................................................................................... 4
2.1.1 History of the CNC Machines and Additive Manufacturing ............... 4
2.2 Inferences drawn out of Literature .......................................................... 5
2.2.1 Design ................................................................................................... 5
2.2.2 Type of Moving Screws ....................................................................... 6
2.2.3 Selection of Motors .............................................................................. 6
2.2.4 Selection of Micro Controller............................................................... 6
2.2.5 Selection of the Coding Language ....................................................... 6
2.2.6 Selection of the fabrication method of the body .................................. 6
2.3 Summary ................................................................................................. 7
Chapter 3 DESIGN AND ANALYSIS .......................................................................... 8
3.1 Design Methodology ............................................................................... 8
3.1.1 Load Evaluation ................................................................................... 9
3.2 Mathematical Model.............................................................................. 11
3.2.1 Assumption ......................................................................................... 11
3.2.2 Material Parameters for Ball Screw ................................................... 11
3.2.3 Free-Body Diagram ............................................................................ 12
3.2.4 Shear force and bending moment Diagram ........................................ 12
3.2.5 Analytical Solution ............................................................................. 13
3.2.6 FEM Solution using ABAQUS .......................................................... 14
3.3 Torque Calculation ................................................................................ 15
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3.4 Critical Speed Calculation ..................................................................... 16

3.4.1 Critical Speed ..................................................................................... 16
3.5 Static Analysis of the Ball Screw in Solidworks ................................... 17
3.6 Dynamic Analysis of the Ball Screw in Solidworks ............................. 18
3.7 CAD Model and Renderings ................................................................. 20
3.7.1 1st Design ........................................................................................... 20
3.7.2 Final Design ........................................................................................ 20
3.7.3 Exploded View of Final Design ......................................................... 21
3.7.4 CAD Representation of Components of Machine .............................. 22
3.8 Summary ............................................................................................... 26
Chapter 4 PHYSICAL MODEL DEVELOPMENT AND TESTING ......................... 27
4.1 Fabrication Process................................................................................ 27
4.2 Instrumentation ...................................................................................... 28
4.3 Testing and Experimentation................................................................. 29
4.4 Chapter Summary .................................................................................. 30
Chapter 5 RESULTS AND DISCUSSION .................................................................. 31
5.1 Simulation Results ................................................................................. 31
5.2 Experimental Setup and Results ............................................................ 34
5.3 Analysis and Discussion ........................................................................ 35
5.4 Chapter Summary .................................................................................. 36
Chapter 6 IMPACT AND ECONOMIC ANALYSIS ................................................. 37
6.1 Social Impact ......................................................................................... 37
6.2 Sustainability analysis ........................................................................... 37
6.2.1. Recovery time.................................................................................... 37
6.2.2. Installation ......................................................................................... 38
6.2.3. Materials used.................................................................................... 38
6.3 Environmental impact ........................................................................... 38
6.4 Hazard identification and safety measures ............................................ 38
6.5 Summary ............................................................................................... 39
Chapter 7 CONCLUSION............................................................................................ 40
7.1 Summary ............................................................................................... 40
7.2 Future Recommendations ...................................................................... 40
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References ........................................................................................................................ 42
Appendices ....................................................................................................................... 43
Appendix A Design Calculations ................................................................ 43
Appendix B 2-D Drawings of CNC Routers and its Components ............. 46

TABLE OF FIGURES

Figure 1-5-1: Gantt Chart ................................................................................................... 3

Figure 3-1-1: CNC Router with 3-Axis Mobility............................................................... 8
Figure 3-1-2: Flow Chart of Design Process ...................................................................... 9
Figure 3-1-3: Y-Axis Load Assembly .............................................................................. 10
Figure 3-2-1: Mathematical Model of Beam Assembly................................................... 11
Figure 3-2-2: Free Body Diagram .................................................................................... 12
Figure 3-2-3: Shear Force Diagram.................................................................................. 12
Figure 3-2-4: Bending Moment Diagram ......................................................................... 13
Figure 3-2-5: Vertical Deflection for cross sectional beam using ABAQUS .................. 14
Figure 3-5-1: Static Analysis of Ball Screw ..................................................................... 17
Figure 3-6-1: Dynamic Analysis of Ball Screw for displacements .................................. 19
Figure 3-6-2: Dynamic Response of the Critical Node in Assembly ............................... 19
Figure 3-7-1: Initial Design .............................................................................................. 20
Figure 3-7-2: Main Components of the Machine-Final Design ...................................... 21
Figure 3-7-3: Exploded View of CNC Precision Router ................................................ 21
Figure 3-7-4: Side Gantry 1.............................................................................................. 22
Figure 3-7-5: Side Gantry 2.............................................................................................. 22
Figure 3-7-6: Supporting Block 1 .................................................................................... 23
Figure 3-7-7: Supporting Block 2 .................................................................................... 23
Figure 3-7-8: Main Gantry Complete Assembly .............................................................. 24
Figure 3-7-9: Z-Axis C-Shaped Movement Structure ...................................................... 24
Figure 3-7-10: Ball Screw (without nut) .......................................................................... 25
Figure 3-7-11: Universal Ball Bearing ............................................................................. 25
Figure 3-7-12: Linear Bearing Housing ........................................................................... 25
Figure 3-7-13: Ball Screw Nut ......................................................................................... 26
Figure 3-7-14: Guide Rods ............................................................................................... 26
Figure 4-1-1: Detailed Bill of Quality .............................................................................. 27
Figure 4-1-2: Physical Model of CNC Precision Router ................................................. 28
Figure 4-2-1: Flow Chart of Machine .............................................................................. 29
Figure 5-1-1: First Mode of Natural Frequency ............................................................... 31
Figure 5-1-2: Second Mode of Natural Frequency .......................................................... 31
Figure 5-1-3: Third Mode of Natural Frequency ............................................................. 32
Figure 5-1-4: Fourth Mode of Natural Frequency............................................................ 32
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Figure 5-1-5: Fifth Mode of Natural Frequency .............................................................. 33

Figure 5-1-6: Natural Frequency Vs Mode No ................................................................ 33
Figure 5-1-7: Graph showing relationship between Frequency (y-axis) Vs Mode No (x-
axis) .................................................................................................................................. 34
Figure 5-2-1: FFT (Fast Fourier Transform) plot in origin for acclelaration ................... 35

Nomenclature

A minimum cross-sectional area of the screw shaft (mm2)

dc mean diameter of collar

dm mean diameter of lead screw

dr screw shaft root diameter(mm)

E modulus of longitudinal elasticity (N/mm2)

f friction coefficient

F load on lead screw

fc collar friction

Fc critical load (N)

g acceleration of gravity(mm/sec2)

I minimum second area moment of inertia of screw shaft cross section (mm4)

ISO International Organization for Standard

L distance between supports (mm)

l lead of ball screw

ncr critical speed

OHSAS Occupational Health and Safety Assessment Series

S.F factor of safety

T total torque

Tc torque required to overcome collar fiction

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Tr driving torque for ball screw

Wsx load on x axis with factor or safety

Wsy load on y axis with factor or safety

Wsz load on z axis with factor or safety

Wx load on x axis

Wy load on y axis

Wz load on z axis

γ specific weight(N/mm3)

λ support factor
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Chapter 1
INTRODUCTION

1.1 Motivation and Background

Computer numeric control (CNC) machines have been ruling the manufacturing industry
since the late 1950s. Material removal processes were the first type of processes which
fall a prey to this advance technology in which computers not only control the overall
process but also changes the feed rate and spindle speeds with respect to the
fluctuations/anomalies present in our work piece. It was not a long shot to predict that very
soon all the processes will be performed using CNC machines.

In the late 1980s (1987 to be precise), the additive manufacturing processes were first
performed using CNC machines and ever since then the entire manufacturing industry has
never looked back to any other technology. Additive manufacturing was initially used to
produce the prototypes of highly complex and expensive products that were not cheap to
manufacture [3]. All types of analysis were performed on these prototypes and then the
expensive product was given a green signal to be manufactured if desired results are
obtained else the corresponding design alterations are performed by the designers. After
the success of CNC in making prototypes, processes of 3D printing, selective laser
sintering (SLS), laminated object manufacturing and other additive manufacturing
processes also started to get performed using CNC routers.

Ever since the additive manufacturing processes are performed on CNC machines, the
problem has been, is of precision. Many improvements have been incorporated in CNC
machines, over the years to achieve the precision by operating/routing it at high speeds. A
lot of time was used to get spent on post-production surface finishing processes to achieve
the desired precision along with good surface finish. To have a better overall plant
efficiency, we are motivated to design and fabricate a CNC precision router with such
accuracy and precision after which surface finish processes can be left because of the high
micron level precision of the manufactured product. By reducing the overall time as a
result of no post production processes in the most ideal case, the efficiency of the small
industry of Pakistan utilizing this router will be increased tremendously resulting in more
prosperous financials of small scale industrial sector of Pakistan.

1.2 Problem Statement

To design, fabricate and test a computer numeric control (CNC) precision router for
additive manufacturing processes on small industrial scale.
 2

1.3 Scope of Work and Expected Outcomes

The prime objective of this CNC precision router is to achieve micron level precision by
reducing all kind of vibrations and surrounding noises. The whole router is sub-divided
into electronic, mechanical and coding sub-assemblies which are further divided into their
respective components. This division is done on the basis of impact on the overall
precision of the router. All electronic and mechanical elements are studied in detail and
the respective significant component selections are made so that the micron level precision
can be achieved.

This CNC precision router is mainly focused on performing the process of additive
manufacturing using a pneumatic head but with some further modifications and using
spindle motors along with respective cutting tools, this router can further be utilized to
perform material removal machining processes with the same micron-scale precision. The
scope of this final year project is limited to additive manufacturing processes only but
micron scale precision for material removal processes is just one of the many promising
future prospects of this router. Micron-scale precision routing for any manufacturing
process is the ultimate expected outcome. Testing of this router to perform additive
manufacturing processes will validate the desired expected outcome to be implemented in
the small industries of Pakistan.

1.4 Report Outline

This report contains the design and fabrication of a CNC precision router, for small scale
industrial applications. The first chapter introduces the CNC precision router and briefly
discusses its history. Second chapter includes the previous research work on additive
manufacturing and CNC routing machines along with its constraints, while the third
chapter deals with detailed analytical and computational calculations, using FEA
technique, and design methodology of each component of the CNC precision router.
 3

1.5 Project Schedule

Figure 1-5-1: Gantt Chart

1.6 Individual and Team Contribution

Research and literature review was performed by each and every member in their
respective fields. Sarmad Ishfaq and Muhammad Shoaib Butt performed the design and
modeling aspects while Saad Ali and Muhammad Ismail Leghari worked on the electronic
and programming aspects of the CNC precision router. On the basis of literature review,
concept design of the precision router was generated by Sarmad Ishfaq and Muhammad
Shoaib Butt. Muhammad Shoaib Butt visited Islamabad/Rawalpindi for initial market
survey and provided Sarmad Ishfaq with the available components dimensions/details.
Sarmad Ishfaq then generated initial CAD model of each component and then assembled
them. Design calculations of different parts were divided among Muhammad Shoaib Butt,
Saad Ali and Sarmad Ishfaq. Muhammad Shoaib Butt and Saad Ali calculated the
dimensions of assigned parts analytically while Sarmad Ishfaq performed the
computational analysis using FEA technique. Muhammad Ismail Leghari developed the
logic, algorithms and software for the router. To finalize the means of procurement, all
group members visited Lahore and met with Qadri group design team as part of the final
market survey. Final dimensions were then shared with each other and BOM was prepared.
Sarmad Ishfaq then modified the CAD model according to changes and generated the 2-
D drawings of each part.
 4

Chapter 2
LITERATURE REVIEW

2.1 Literature review

This chapter consists of a brief history of the CNC Machine and Additive Manufacturing
(AM) and a summary of the work progress made by different companies in both the
prospects.

2.1.1 History of the CNC Machines and Additive Manufacturing

CNC stands for Computer Numerical Control and is outgrowth of the term “NC” which
stands for “Numerical Control”. The basic idea of CNC is to control a machine via
computer [2].

The first commercial CNC machines were built in 1950’s. It proved to be very cost
effective and allowed tremendous increase in productivity. Before CNC the only
automation opportunity available to the manufacturers was in the form of hydraulic tracer
systems which used hydraulics to move cutting tools in a specified path (template) [2].
The amount of automation was tremendously increased by CNC. Nowadays it is the
dominant methods for machining processes, although traditional manual machining is still
quite common.

CNC machines usually require an operator and a CNC programmer to write the program
for automation. Programs are written in a special language called “G-Code”. G-Codes
were first used in MIT servomechanism laboratory in 1958 and later standardized in 1960.
Programs may either be directly coded, or CAM software may be used to convert a CAD
drawing into G-Code [2]. Usually a microcontroller such as Arduino or Raspberry Pi is
used to control the machine movements via motors. The programming languages used are
JAVA, C sharp or PYTHON. PYTHON, however, is preferred because of its line to line
compilation, file handling and data base, GUI compatibility and pipeline tasking (using
output of a process as a direct input to another process without any interference) [6].

Motors and lead/ball screws are used in combination for linear motion of axis [5]. Motors
used are either servo or stepper motors. Stepper motors are preferred choice for CNC
machines because of their small rotational steps (high resolution) although it lacks
feedback system and can be considered open loop.

Many types of CNC machines are being used today for commercial purposes. Most
common of them are CNC Lathe Machines, Milling Machines, Engraving Machines,
EDM Machines, water jet cutters and CNC routers. CNC routers are usually CNC Mill
that uses a gantry configuration used for cutting wood but this may not be the case.
 5

Recently many more creative uses of the CNC routers have been introduced by the
enthusiasts around the globe.

Additive manufacturing (AM) first emerged in 1987 with stereo lithography (SL) from 3D
Systems [1].It is the process of building up a 3D component by adding layer upon layer of
material. The first AM system in the world was SLA-1 where SLA stands for Stereo
Lithography Apparatus. It was followed by SLA 250 and Viper SLA products. Many
companies commercialized SL system during this time period. In 1991, three AM
technologies by different companies were introduced. The AM technologies are fusion
deposition modelling (FDM), solid ground curing (SGC) and laminated object
manufacturing (LOM). In 1992, selective lase sintering (SLS) and Soliform Stereo
Lithography were introduced. In 1993, direct shell production casting (DSPC) using inkjet
mechanism was commercialized. Many other AM systems like Quick Cast, Model Maker,
AeroMet, ThermoJet, Solid Center, Quadra, Prodigy and Optoformetc others were
commercialized in next decade. All these processes use different techniques and have
different working principles [1].

Additive manufacturing has the ability to produce almost any part. It is used to bring
precision and accuracy to smaller components rather than larger and complex parts. Over
the years additive manufacturing has found its uses in medicine, aerospace, motor
vehicles, consumer products, business machines and military equipment [10].

Due to expiration of patents, there has been an increase in research and development of
additive manufacturing processes such as projector based digital light processing (DLP)
technology, multi-color and multi-material processes, printed electronics, printed sugary
food and ceramics, sand printing, low cost 3D printers, direct energy deposition (DEP),
powder bed fusion, laser sintering and many more [10].

2.2 Inferences drawn out of Literature

CNC machines are the basic building element of today’s modern manufacturing industry.
With the passage of time and increase in complexity the need for precision and speed has
increased exponentially. Efforts are being made to get maximum precision at very high
speed.

The precision and speed depends on the following:

2.2.1 Design
Traditional CNC machines were mostly made on knee and column design which were
quite efficient for material removal processes as they provided a full supported workspace
to counter the high cutting forces. But with the development of additive machining
processes the gantry design are mostly preferred. The reason behind the selection of gantry
design is the ease of movement of the tool in all 3-axis and its stable structure. Gantry
 6

design further consists of 2 type’s i.e. fixed and moving gantry. In fixed gantry the table
moves in 2 axes (x and y axes) and tool moves only in z-axis while in moving gantry the
table remains stationary and tool moves in all 3 axis. Considering the structural stability
we have selected the fixed gantry design for our machine.

2.2.2 Type of Moving Screws

The speed and precision of a CNC precision router is highly affected by the type screws
used to move table and the screws. Ball screws are used as they have rollers inside that
provide negligible friction during the movement of table or tool in respective direction.

2.2.3 Selection of Motors

In order to provide motion in the respective directions we need motors. Selection of the
motors is one of the most critical decisions an engineer has to make while designing a
CNC router. Different types of motors are available in market. Mostly stepper motors are
used in this regard as they provide a step motion of as low as 1.8 degree which is quite
helpful in maintaining the precision of the machine. After selecting the type the motor is
selected on the basis of its current rating and the torque it provides.

2.2.4 Selection of Micro Controller

The selection of appropriate micro controller is a crucial matter as it provides a connection
between the machine and the input that machine receives from operator. The function of
the micro controller is to receive the inputs from the operator and interpret it into low level
language that machine can understand and perform the task as instructed by the operator.
The selection of the micro controller depends upon the number of interrupts of the
machine.

2.2.5 Selection of the Coding Language

Micro controller needs to be programmed before it performs the task of interpreter
between the machine hardware and the operator. This programming is done in a high level
programming language like C++, C-sharp and python etc.

2.2.6 Selection of the fabrication method of the body

There are two methods of fabrication of the body of machine. First method includes the
used of rivets and bolts while the second method is to get the whole body casted. The
disadvantage of the first method is that with the passage of time machine loses its
precision due to loosening of rivets and misalignment. While in case of second method
all these disadvantages are ignored and it reduces vibrations and noise. So casting was
selected as the fabrication method.
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2.3 Summary
Keeping in mind the literature review and all the aspects discussed, the final decisions
were made. Depending upon the stability and ease of movement in workspace fixed gantry
design was selected. In order to maintain precision and speed ball screws were selected as
the moving screws. 23 NEMA stepper motors were used as driving sources. Python
language was selected to program Raspberry Pi 3 micro controller depending upon the
number of interrupts of the machine. Structural steel grade 1045 was used for casting the
body of the machine.
 8

Chapter 3
DESIGN AND ANALYSIS

3.1 Design Methodology

Figure 3-1-1: CNC Router with 3-Axis Mobility

The Figure 3-1-1 shows the router movement axis and the assemblies associated with it.
The ball screws and the supporting shafts have to bear the loads of each assemblies. The
design and analysis of the router is carried out in the following steps.
 9

Literature Review

Initial CAD Model

Load Calculations on each Axis for Ball Screw Selection

Mathematically Model the Load Assembly

Solving the Model Analytically and using ABAQUS to justify Dimensions of Ball Screw

Torque Calculation for Motor Selection

Critical Speed Calculation for Ball Screw

Static Analysis of Assembly in Solidworks to justify the dimensions

Natural Frequency Analysis in Solidworks to justify the dimensions

Linear Dynamic Analysis in Solidworks to justify the dimensions

Final CAD Model

Figure 3-1-2: Flow Chart of Design Process

3.1.1 Load Evaluation

For X-Axis

In X-axis the router has to move the bed on which the substrate has to land. The
calculations are as follows.

 Bed dimensions = 250mm * 250mm *10mm

 Material = AISI 1045 Steel
 Density = 7850 kg/m3
 Mass = 5.5 kg
 Wx = 54 N
 S.F = 1.5
 Wsx = 81 N
 10

For Z axis

 Mass assumed = 2 kg

Wz = 19.6 N
S.F = 1.5
Wsy = 29.4 N

For Y-Axis

Centre of mass
(CM)

Figure 3-1-3: Y-Axis Load Assembly

The Figure 3-1-3 shows the Y-Axis assembly. The loads are applied eccentrically so a
moment (M) is also applied the center of the Ball Screw. The CM is shown on the Figure
is calculated using Solidworks. Mass of the assembly is also calculated using Solidworks.

 Mass = 8 kg
 Distance of CM to center of Ball Screw (d) = 54 mm

Wy = 78.5 N
S.F = 1.5
Wsz = 118 N
M = (108 N) (54 mm) = 6.4 Nm

So the critical load (Fc) will be applied on Y-Axis because the load applied is the greatest
and a moment is also applied as well. This will now be modelled mathematically to be
solved analytically and using FEM.

Fc = 118 N
 11

3.2 Mathematical Model

The diameter of the ball screw is to be determined. For this purpose the ball screw is
modelled mathematically using beam theory from Mechanics of Solid. The following
assumptions are required for the modelling.

Figure 3-2-1: Mathematical Model of Beam Assembly

3.2.1 Assumption
1. The ball screw behaves like a simply supported beam.
2. Cross section area the beam is circular.
3. As bed has extended size and there is some load over the bed. Uniformly
distributed load of 1180 N/m is applied from 0.2m to 0.3m as shown in Figure 3-4.
4. Moment of magnitude 5.6 N.m. is also applied at the center of beam at 0.25 m.

3.2.2 Material Parameters for Ball Screw

 AISI 6150 alloy steel
 Density 7850 kg/m3
 Modulus of Elasticity 200 GPa
 Poisson Ratio 0.3
 Yield Strength 415 MPa
 12

The length of the ball screw is 500 mm or 0.5 m. The model is solved using different
diameter of ball screw. For our precision applications we want deflection of ball screw
due to loading to be less than 0.5 mm. Analytical solution are carried out using equations
of beam deflections and are compared with the solutions of FEM using abaqus to ensure
correct application of equations and boundary conditions. The results of analytical and
FEM techniques are illustrated in Table 3-2.

3.2.3 Free-Body Diagram

Figure 3-2-2: Free Body Diagram

Reactions at each end of beam are calculated and shown in Figure 3-2-2.

3.2.4 Shear force and bending moment Diagram

Figure 3-2-3: Shear Force Diagram

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Figure 3-2-4: Bending Moment Diagram

3.2.5 Analytical Solution

The following equations were developed to find the maximum displacement of shaft.

1 243.85𝑥 3 −39.77𝑥
𝑦1 = E ∗ ( ) for 0 < x < 0.2m (3.1)
d4

1 −1001.68𝑥 4 +1045.075𝑥 3 −240.388𝑥 2 −7.72346𝑥−1.6025

𝑦2 = E ∗ ( ) for 0.2m < x < 0.25m (3.2)
d4

1 −1001.68𝑥 4 +1045.075𝑥 3 −305.5775𝑥 2 −24.86945𝑥−5.67637

𝑦3 = E ∗ ( ) for 0.25 < x < 0.3m (3.3)
d4

1 −156.86𝑥 3 +235.295𝑥 2 −83.2988𝑥−2.43672

𝑦4 = E ∗ ( ) for 0.3 < x < 0.4m (3.4)
d4
 14

3.2.6 FEM Solution using ABAQUS

Figure 3-2-5: Vertical Deflection for cross sectional beam using ABAQUS

Table 3-1 gives the max deflections and the % differences among the analytical and
computational results. The differences are very small and within the range of allowable
accuracy. The diameter and lead of different ball screws are taken from SFU Catalogue.
For our requirement we have selected 16 mm as the diameter of lead screw for which
deflection are less than 0.5 mm.

Table 3-1: Comparison of Analytical and FEM results

Major Lead Max Deflection Max Deflection using %

Diamete (mm) Analytically (mm) ABAQUS (mm) Difference
r (mm)

12 4 1.48 1.493 0.878378378

16 4 0.42 0.4128 1.714285714

20 4 0.19 0.194 2.105263158

25 4 0.078 0.0796 2.051282051

32 4 0.029 0.0293 1.034482759

40 5 0.0122 0.01223 0.245901639

50 10 0.0051 0.005046 1.058823529

 15

3.3 Torque Calculation

For our CNC router ball screws are used for the movement of axis. The torque required to
rotate ball screw is given as:

(3.5)

It is assumed that ball screws are single threaded so lead ‘l’ will be equal to the pitch of
screw. For friction coefficient ‘f’, generally the material used for power screws is steel for
the screw and the nut is made of bronze. This is to reduce the wear of the mating materials

Generally the sliding coefficient of friction for the power screws is about 0.10-0.15. The
table for friction coefficients is taken from Shigley’s Mechanical Engineering Design

Table 3-2: Friction Coefficient

Screw Nut Material

Material
Steel Brass Bronze Cast Iron

Steel, dry 0.15–0.25 0.15–0.23 0.15–0.19 0.15–0.25

Steel, 0.11–0.17 0.10–0.16 0.10–0.15 0.11–0.17

machine oil
.

Bronze 0.08–0.12 0.04–0.06 — 0.06-0.09

In addition to frictional forces of ball screw, the motor also have to provide torque to
overcome the frictional force of thrust bearing. A thrust bearing is installed to give support
to the lead screw. Ordinary ball bearing cannot be used since it cannot bear axial forces, it
can only withstand radial forces. Torque required to overcome collar fiction is as follows

(3.6)

Mean Diameter of collar can be calculated as:

(3.7)
 16

So, Total required torque will be

𝐹.𝑑𝑚 𝑙+𝜋𝑓𝑑𝑚 𝐹.𝑓𝑐.𝑑𝑐

𝑇= ( )+ (4)
2 𝜋𝑑𝑚−𝑓𝑙 2

3.4 Critical Speed Calculation

3.4.1 Critical Speed

The speed that excites the natural frequency of the screw is referred to as the critical speed.
The screw will resonate regardless of screw orientation or whether the nut rotates about
the screw.Critical speed varies with diameter, unsupported length, end fixity, and speed
(rpm). Shaft straightness and assembly alignment can also play a role, so manufacturers
recommend that maximum speed be limited to 80% of theoretical critical speed.

Calculate critical speed, ncr, in rpm from:

𝜆2 𝐸∗𝐼∗𝑔 60
𝑛𝑐𝑟 = √ ∗( ) (5)
𝐿2 𝛾∗𝐴 2𝜋

L = 500 mm
E = 2.05×10^6 N/mm^2
I = π*d^4/64
g = 9810 mm/s^2
γ = 7.71×10-5 N/mm^3
A = π*d^2/4.

In addition, λ is a factor determined by the ball-screw support method, where:

 One end fixed and the other free, λ = 0.59π.

 Both ends simply supported, λ = π.
 One end fixed and the other simply supported, λ = 1.25π.
 Both ends fixed, λ = 1.49π.

As previously defined our ball screw is simply supported.

 17

Table 3-3: Critical Speeds for various diameters of ball screws

Major Diameter Lead (mm) Torque ncr (rpm)

(mm)

12 4 0.289968099 5702.357764

16 4 0.37384134 7603.143686

20 4 0.457938052 9503.929607

25 4 0.563193885 11879.91201

32 4 0.710668627 15206.28737

40 5 0.888335784 19007.85921

50 10 1.144845129 23759.82402

3.5 Static Analysis of the Ball Screw in Solidworks

Previously we have analyzed the mathematical model in FEM software ABAQUS. Now
the 3D model is to be checked for deflection in real conditions. The boundary conditions
and forces applied are shown in Figure 3-5-1. Gravity is also taken into account to make
the analysis more realistic.

Figure 3-5-1: Static Analysis of Ball Screw

 18

The result of the analysis showed the maximum deflection due to static loading to be 0.28
mm.

3.6 Dynamic Analysis of the Ball Screw in Solidworks

The ball screw operates at certain rpm (Hz) so there is a need for dynamic analysis to
ensure that the natural frequency of the structure does not resonates with the operating
frequency.

Our working conditions are given in the table below.

Table 3-4: Working Condition of the Router in different Units

mm/s Rpm rad/s Hz

20 19.1 2 0.32

60 57.3 6 0.95

The table below shows the natural modes of the structure.

Table 3-5: Natural Modes of Frequency

Frequency Number Rad/sec Hertz Seconds

1 1188.5 189.16 0.0052865

2 1192.4 189.77 0.0052695

3 3478.2 553.57 0.0018064

4 3490.9 555.6 0.0017999

5 6929.8 1102.9 0.00090669

 19

As inferred from the results, we can safely assume that our structure operating frequencies
in not within natural frequency range.

Now to find the displacements during dynamic motion of the screw the model is analyzed
in Solidworks for the linear displacement in the working conditions. The results are plotted
below.

Figure 3-6-1: Dynamic Analysis of Ball Screw for displacements

The Figure 3-6-1 shows the maximum displacements that occurs during working
conditions and Response Graph of the center point of the ball screw is shown the Figure
3-6-2 in the working range.

Figure 3-6-2: Dynamic Response of the Critical Node in Assembly

 20

3.7 CAD Model and Renderings

3.7.1 1st Design

The following figure shows the initial design that we came up with basic parameter and
primary components.

Figure 3-7-1: Initial Design

3.7.2 Final Design

The following figure shows the complete assembly and its parts that will be used in CNC
Precision Router. This is the final complete design with all the components (primary and
secondary). The Stepper Motors, Screws, Universal Bearing, Joining Mechanisms for the
gantry and supporting structure and all the required components for fabrication are shown
in the Figure 3-7-2. This model will be referred to in the fabrication of router.
 21

Figure 3-7-2: Main Components of the Machine-Final Design

3.7.3 Exploded View of Final Design

The exploded view gives a good idea about how the machine that is to be given for
fabrication will be joined and assembled. The Figure 3-7-3 below shows the exploded
assembly of CNC Precision Router.

Figure 3-7-3: Exploded View of CNC Precision Router

 22

3.7.4 CAD Representation of Components of Machine

Figure 3-7-4: Side Gantry 1

Figure 3-7-5: Side Gantry 2

 23

Figure 3-7-6: Supporting Block 1

Figure 3-7-7: Supporting Block 2

 24

Figure 3-7-8: Main Gantry Complete Assembly

Figure 3-7-9: Z-Axis C-Shaped Movement Structure

 25

Figure 3-7-10: Ball Screw (without nut)

Figure 3-7-11: Universal Ball Bearing

Figure 3-7-12: Linear Bearing Housing

 26

Figure 3-7-13: Ball Screw Nut

Figure 3-7-14: Guide Rods

3.8 Summary
In this chapter design and analysis for the Precision CNC Router is carried out. The
dimensions are finalized. Mathematical model of the critical load assembly is developed
and solved using analytical and using ABAQUS. Torque and critical speeds are calculated.
The results from the beam analysis is justified using Static and Dynamic analysis using
Solidworks. In the end the calculations provides surety that with given dimensions the
structure will be stable statically and dynamically.

The complete CAD Model with all its main components are shown as well. The design is
ready to pass on to the fabrication stage.
 27

Chapter 4
PHYSICAL MODEL DEVELOPMENT AND TESTING

4.1 Fabrication Process

For fabrication of CNC Precision Router the facilities of the Qadri Brothers Group was
acquired. The detailed Bill of Quality in shown in Figure 4-1-1 was prepared along with
complete final drawings (Appendix 2) with finalized dimensions was forwarded to them.
Few meetings were also conducted with their senior design engineers to discuss the
stability and precision of the router. After successful meeting, the design went through
minor changes and it was forwarded to the manufacturing facility of Qad Bros Lahore.

The structure of the main gantry was made from ASTM A36 Steel because it was rigid
and could cater the vibrations easily that can develop in our structure. The material was
procured from Qadri Group. The universal bearing were also purchased from the Qad
Bros factory inventory.

The unused ball screws that were used were procured from Ali Express, China. Similarly
the linear ball bearing was also purchased from the same source.

Both of the side gantry, supporting blocks, X-Axis table and the Z-Axis movement
structure as shown in Figure 4-1-1 were prepared to the best possible accuracy by using
the CNC machines.

Figure 4-1-1: Detailed Bill of Quality

 28

Then the whole model machine as shown in the Figure 4-1-1 was assembled with the help
of the workers at Qadri Group. For the joining purposes nuts and bolts were used. For
alignment of the supporting blocks dowel pin was used in addition to nuts and bolts to
ensure the alignment of the structure.

After the assembly was complete the machine was checked for any defects or
misalignment. When fully satisfied about the machine build, surface finishing was applied.
After the whole fabrication process, the physical model of the machine was developed
which is shown in Figure 4-1-2.

Figure 4-1-2: Physical Model of CNC Precision Router

4.2 Instrumentation
While working on the fabrication of precision router one of the major hurdles was the
selection of the instrumentation components.

 Infrared Sensors: We used SHARP Infrared sensors GP2Y0A51SK0F for

limiting the work area of the machine. These were placed at the end of the ball
screws. These sensors provided a voltage input the by means of analogue to
digital converter are fed to the Raspberry Pi microcontroller which then cuts the
motor power. These were installed to protect the ball screws plus to provide the
zero and maximum reference points to machine for routing purposes.
 29

 Analog to Digital Converter: This converter was installed in between the

micro-controller and infrared sensors because sensors give analog output while
the raspberry pi accepts digital so a converter was installed.
 Motor Drivers: TB-6560 single axis motor drivers are installed between the
controller and the stepper motors. They act as H-bridge and interpret the signals
sent by the controller and operate the motors accordingly.
 Power Supply: Power supply of 24 volts has been used to power the machine.
Its input goes to the three TB-6560 drivers to run the motors.
 Raspberry Pi 3: In order to operate the machine the stepper motors installed a
raspberry pi 3 micro controller is installed that not only acts as an bridge between
the user and machine but takes input too.
 Monitor: A monitor is connected to the micro-controller to display the
machine’s GUI and helps the user to operate the machine.
 Keyboard & Mouse: These input devices are connected to the micro-controller
in order to get input from the user and forward it to the machine.

The diagram below shows the flow chart of the machine.

Figure 4-2-1: Flow Chart of Machine

4.3 Testing and Experimentation

Two types of testing were carried out to ensure the proper movement of the router.

1) Physical Testing

After the physical model is coupled to the electronics and software interfaces it is to be
tested for its movement is each direction without any blockage and play.

The movement of router in each axis X, Y and Z were checked with the limit switches
installed to prevent damage to machine.
 30

The machine was given instructions using open source GUI available called Mach 3 which
give signals to steppers motors. Each of the movement assembly of their respective axis
were tested with back and forth motion for 10 cycles.

The movement of the structure was found to be smooth and the testing confirmed it. The
motors were coupled properly to the ball screws. The RPM of the motor shaft and coupled
the ball screw were found using the Tachometer which turned out to be same for both the
shafts within acceptable range.

2) Vibration Testing and Experimentation

Vibrations are a matter of concern regarding the accuracy and precision of the router.
There are multiple sources of vibrations such as mechanical joints, motor, eccentric
loading on the ball screws and supporting shafts etc. The purpose of this testing is to
analyze, compare and make efforts to reduce the vibrations and hence increase the
precision and accuracy of the CNC precision router.

It is important to limit vibrations as their presence results in poor accuracy, surface finish
of the work pieces. Vibrations can damage other machine parts or result in complete failure
which would require repairs. Since, machine cannot be repaired while working, thus it is
costly. Vibrations also decrease the efficiency of the machine.

The purpose of this testing is to model and analytically measure the deflections and
vibrations produced in the CNC precision router. The analysis is done on shafts and C
section of the machine (shown in Figure 1).

The instruments used are accelerometer, Myrio card and a Personal Computer.
Reason for using accelerometer is that natural frequency of our system is very high and
displacement in our shafts is very low to be sensed by any other sensor with less
sensitivity. Impact hammer testing was also done with accelerometers after calibration and
readings are presented in Chapter 5.

4.4 Chapter Summary

In this chapter the whole fabrication process from final design to physical model
development has been explained. The process of instrumentation from initiation to
completion is briefly elaborated. The machine was tested physically and with vibration
sensors to determine its rigidity.
 31

Chapter 5
RESULTS AND DISCUSSION

5.1 Simulation Results

Natural frequency analysis was performed on our model and the results for different modes
are gives below.

Figure 5-1-1: First Mode of Natural Frequency

Figure 5-1-2: Second Mode of Natural Frequency

 32

Figure 5-1-3: Third Mode of Natural Frequency

Figure 5-1-4: Fourth Mode of Natural Frequency

 33

Figure 5-1-5: Fifth Mode of Natural Frequency

Frequency vs Mode No is given in the following graph. The graph shows that as we
increase the mode no. frequency increases exponentially.

Figure 5-1-6: Natural Frequency Vs Mode No

Above graph can be closely represented by a fourth order equation.

y = -1.255x4 + 22.839x3 – 102.34x2 + 179.56x

 34

Where y represents frequency in hertz (Hz) and x represents mode no as positive integers.

Chart Title
450
400 y = -1.255x4 + 22.839x3 - 102.34x2 + 179.56x

350
300
250
200
150
100
50
0
0 1 2 3 4 5 6

Figure 5-1-7: Graph showing relationship between Frequency (y-axis) Vs Mode No (x-
axis)

5.2 Experimental Setup and Results

The accelerometer was mounted on the shaft which was connected to the Myrio Card
which was in turn connected to the PC. Command signal was given from MACH 3 to
move the precision router and readings of acceleration against time were taken. Then
hammer testing was done and readings were taken again which gave us a peak. These
readings were in time domain. These readings were converted to frequency domain and
plotted using FFT (Fast Fourier Transform) using ORIGIN. The graphs obtained are given
below
 35

Figure 5-2-1: FFT (Fast Fourier Transform) plot in origin for acclelaration

Above graphs shows acceleration (g) vs time (sec). The peak shows the impact from
impact hammer testing.

Above graphs gives the value of frequency at the nodes. The first node gives 95 Hz while
the second node gives 107.

5.3 Analysis and Discussion

The natural frequencies obtained from experimental show that the vibrations in the system
are too small to be observed by a sensor with less sensitivity. This shows that the setup
 36

that was used to study vibrations is very stable statically as well as dynamically. The first
and second mode frequencies obtained from simulation closely resemble that obtained
experimentally.

5.4 Chapter Summary

Natural frequency analysis for the C-Shaped Movement structure was conducted along
with the shafts. The same results were verified with experimental setup of accelerometer
and hammer testing. Upon analysis of the system we conclude that the system is very
stable with first and second mode from both closely confirming the experimental data.
 37

Chapter 6
IMPACT AND ECONOMIC ANALYSIS

6.1 Social Impact

CNC precision router can be used in many industries such as automobile, machine tools
production, aerospace, electronics as well as medical and dental tools industry. Since it
will be used in industry, it will generate a considerable amount of revenue. Cost of
manufacturing will decrease as there is no material waste and energy consumption is
efficient. Also it requires a skillful operator so it will also open employment opportunities
in the industry.

This project can also help increase in the automation of industry in the areas where only
conventional machining is being used for most processes. Automation smoothens the
production line, requires less work force and decreases complexity of the process.
Although this will result in the loss of jobs of manual workers, it will generate job
opportunities for people skilled in CNC.

Another social aspect of this project is that it can become a source of knowledge for
people pursuing mechanical engineering and industrial engineering. People can use it as a
base to find a wide number of applications and derivatives.

6.2 Sustainability analysis

CNC machines are the future of the conventional machining and soon they will replace
most of the conventional machining processes (except for a very few operations that can
only be done by conventional machining). So it is safe to say that CNC precision router
can be installed in long term projects given that they are properly and regularly maintained.

6.2.1. Recovery time

For the payback period, the CNC precision router is supposed to be implemented in a
manufacturing facility. Assuming constant inflation rate and fixed price of electricity,
then,

Taking initial cost of the project Rs.106090/-, transportation charges Rs.20000/- and
maintenance cost of PKR 10000/-. The total project expanses become Rs. 136090/-

Considering the fact that the price of a CNC router worldwide is almost 1.2 million Rs,
we will be able to recover our investment by selling only 1 unit.
 38

6.2.2. Installation
The CNC precision router is basically designed to be used in small scale manufacturing
firms. So it will be installed in those firms. It will run smoothly for moderate speeds.
Although it is being used for additive manufacturing, it can also be installed in the material
removal industry with small design changes.

6.2.3. Materials used

Structure of CNC precision router is mainly based on ASTM A36 steel while ball screws
are made of of AISI 6150 alloy steel. The gantry structure can be made in fabricated in
Pakistan but ball screws along with linear bearings, motors and driver circuits are
imported.

6.3 Environmental impact

The structure of our machine is made of ASTM A36 which is a low carbon steel. It is
commonly used in machining and fabrication and can easily be recycled in a foundry. The
ball screws are made of AISI 6150 alloy steel which can also be recycled. The router is
being used for additive manufacturing processes so there are no harmful gases such as
ionized hydrogen being produced. The major environmental impact are the removal of
waste material which is minimal in this case and considerable noise generated by the
stepper motors. The noise of motors can be suppressed by using noise reduction brackets,
running the motor at low to moderate speeds and micro-stepping. The waste can further
be minimize by optimization of the process being done on the router. As ASTM A36 is
easily weld-able, the fabrication process is fairly simple and consists of machining the
steel plates and welding them rather than requiring specific strength materials and casting
processes. Hence it can be considered as more environmental friendly than the
conventional machines.

6.4 Hazard identification and safety measures

Since this router is not being used for material removal processes, therefore most of the
hazards to labour, machine and the environment as in the conventional machining are
already eliminated. There was no hazard faced by us during the working of the machine.
However, there is still a possibility of structural failure and machine operator must always
use a protection gear to avoid any accident. Machine weight is high due to its thickness
and material used so proper supports should be provided on which machine is going to
work. Furthermore, machine should be stopped before carrying any maintenance.

During the fabrication of this process many processes were included which are potential
hazards. These include gas cutting of material, machining, welding and grinding of the
sheets. The safety measures followed against these are published by many safety standards
such as ISO and OHSAS. It is necessary to follow them in order to avoid any injury
causing accident.
 39

6.5 Summary
This chapter discusses the social, economic and environmental aspect of our project. The
impact of router is studied during manufacturing and after installing and running of the
router. Since, this project was designed to incorporate multiple heads, it has the capability
of tapping into wide range of industries. Its cost is low, profit is high and suitable for small
scale firms.
 40

Chapter 7
CONCLUSION

7.1 Summary
The objective of this Final Year Project was to design and fabricate a 3-Axis CNC
precision router with a precision of micron level. This objective was achieved with the
help of proper designing, selecting the standardized ball screws, bearings, motors, driver
circuits and a powerful microcontroller. In designing, both analytical and software
methods, static as well as dynamic, were used to find the deflections, vibrations and torque
in the critical parts of machine and design was modified many times to obtain a stable
working machine. Most of the components were imported from China to assure precision.

ASTM A36 steel was selected to be the material for our main gantry structure because of
its greater machinability, weld ability and stability towards vibration inducing forces. Nuts
and bolts were used for the parts to be removed for maintenance while welding was used
on other parts of the gantry as a joining mechanism.

The machine was tested in GIKI and it routed in all 3-axis perfectly. The noise from motors
was minimum and running was smooth.

7.2 Future Recommendations

Additive manufacturing and CNC routers are a wide field of research and applications.
Recently with the commercialization of 3D printers they have become even more famous
and has peaked interest in people. People have started building their own 3D printers but
the lack of proper technical knowledge as well as novelty of the technology impedes their
progress. We identified few aspects of the CNC precision router that will surely help in
someone future if he/she works on it. The suggestions are as follow:

1) Know what you want to do

You should be clear about what you want to make i-e your objectives of the project. Do
your analytical calculations by different mathematical models to optimize the design.

2) CAD/CAM

At least one member of your group should have knowledge of any CAD/CAM software.

3) Design according to the standards

Make sure that your design incorporates all the components (bearings, supports, bolts and
nuts, screws, ball screws and motors) according to the standard because customized
 41

components take time and increase complexity of the project. Also if you do not use
standardized dimensions then the fabrication will not go as smoothly as you would
imagine.

4) Do your market survey

Make sure that you do the market survey before going into fabrication phase or better yet
in the design phase. This will tell you about your limitations and what to do next.

5) Make sure you correctly select the components you want to buy

If you are going to buy a component, you should be 100% sure about it. e.g if you are
going to buy a stepper motor , you should know all about its specifications. Similarly if
you are going to buy a ball screw, make sure you pitch, diameter and thread length are the
same as in the design.

6) Seek help from other faculties

Since this not a purely mechanical project, you need to seek help from other faculties such
as electronics, computer science and material science. Start working on your software and
electronics part as soon as possible as being a mechanical engineer you lack the knowledge
in this field and need to come up.

7) Use of blogs

There are many blogs on the internet where you can get your queries answered. Also you
can find answers to your questions already explained. These blogs include cnczone, quora
and many other blogs related to CNC machining and 3D printing. However, you should
be aware that these blogs are open source and everyone will not give correct answer. You
should be extremely careful and cross check an answer you get from a blog.
 42

References

[1]T. Wohlers, Wohlers report 2014, 1st ed. Fort Collins, Col.: Wohlers Associates, 2014.

[2]"CNCCookbook: Be a Better CNC'er", Cnccookbook.com, 2007. [Online]. Available:

http://www.cnccookbook.com. [Accessed: 20- Dec- 2016].

[3]"Stepper Motor Calculator", Daycounter.com, 2005. [Online]. Available:

http://www.daycounter.com/Calculators/Stepper-Motor-Calculator.phtml. [Accessed: 17-
Nov- 2016].

[4]"Elastic Bending Theory", Roymech.co.uk, 2009. [Online]. Available:

http://www.roymech.co.uk/Useful_Tables/Beams/Beam_theory.html. [Accessed: 15-
Dec- 2016].

[5]Ball Screws Product Reference Guide, 1st ed. NSK, pp. 2-8.

[6]"Learn Python - Free Interactive Python Tutorial", Learnpython.org. [Online].

Available: https://www.learnpython.org/. [Accessed: 15- Sep- 2016].

[7]Microstepping Programmable Stepper Motor Driver With Stall Detect and Short
Circuit Protection, 1st ed. Allegro, pp. 13-25.

[8]R. Budynas, J. Nisbett and J. Shigley, Shigley's mechanical engineering design, 1st ed.
New [9]History of additive manufacturing, 1st ed. WOHLERS ASSOCIATES, INC,
2014, pp. 1-20. York: McGraw-Hill, 2011.

[10]"Practical Applications & Uses | Additive Manufacturing | SPI Lasers", SPI Lasers.
[Online]. Available: http://www.spilasers.com/whitepapers/practical-applications-and-
uses-for-additive-manufacturing/. [Accessed: 10- Jan- 2017].
 43

Appendices

Appendix A Design Calculations

Calculation of Deflection

Consider the figure shown in 3-2-2. The ball screw is considered as a circular simply
supported beam. The material is supposed AISI 1045 with Young’s Modulus of 2*1011
Pa. The reactions at the ends are calculated as.

RA+RB=118N

∑MA=0

RB*(0.5)=1180*(0.3-0.2)*0.25-6.4

RB=46.2N

RA=118-46.2=71.8N

Section 1 0<x<0.2

M1=71.8x

According to Elastic Bending Theory

d2 𝑦 𝑀
= (A)
dx 2 EI

πd4
I=
64

Integrating Eq(A) for M1

𝑑𝑦1 71.8𝑥 2
EI = + C1 (1)
𝑑𝑥 2

71.8𝑥 3
𝑦1 = + C1 𝑥 + C2 (2)
6
 44

Section 2 0.2<x<0.25

M2=-590x2+307.8x-30

Integrating Eq(A) for M2

𝑑𝑦2 −590𝑥 3 307.8𝑥 2

EI = + − 23.6𝑥 + C3 (3)
𝑑𝑥 3 2

−590𝑥 4 307.8𝑥 3 23.6𝑥 2

EI𝑦2 = + − + C 3 𝑥 + C4 (4)
12 6 2

Section 3 0.25<x<0.3

M3=-590x2+307x-30

Integrating Eq(A) for M3

𝑑𝑦3 −590𝑥 3 307.8𝑥 2

EI = + − 30𝑥 + C5 (5)
𝑑𝑥 3 2

−590𝑥 4 307.8𝑥 3 30𝑥 2

EI𝑦3 = + − + C5 𝑥 + C6 (6)
12 6 2

Section 4 0.3<x<0.5

M4=-46.2x+23.1

Integrating Eq (A) for M4

𝑑𝑦4 −46.2𝑥 2
EI = + 23.1𝑥 + C7 (7)
𝑑𝑥 2

46.2𝑥 3 23.1𝑥 2
EI𝑦4 = − + + C7 𝑥 + C8 (8)
6 2
 45

By calculating Eq (1) to Eq(8) simultaneously the equations obtained for deflection in each section
are

1 243.85𝑥 3 − 39.77𝑥
𝑦1 = ∗( )
E d4

1 −1001.68𝑥4 + 1045.075𝑥3 − 240.388𝑥2 − 7.72346𝑥 − 1.6025

𝑦2 = ∗ ( )
E d4

1 −1001.68𝑥4 + 1045.075𝑥3 − 305.5775𝑥2 − 24.86945𝑥 − 5.67637

𝑦3 = ∗( )
E d4

1 −156.86𝑥3 + 235.295𝑥2 − 83.2988𝑥 − 2.43672

𝑦4 = ∗( )
E d4
 46

Appendix B 2-D Drawings of CNC Routers and its Components

47
48