ABSTRACT

The main aims of the current work are to explore the theoretical and technical procedures for design,
fabricate, assembly, and testing of the electromechanical subsystems for developing a high precision
cost-effective mini three-axis vertical CNC milling machine with an easy interface, high speed, less
power consumption, safety and durable for rapid prototyping machining, small parts and engraving
small features in the electrical and medical industry. In manufacturing industry, portable CNC milling
machine is important to produce a product. This project describes a design and fabrication of portable
CNC milling machine. This project utilized operating principles of CNC milling machine where it can
move in 3 axes specifically X, Y and Z. For this project Fusion 360 software was used to generate the
G-code for milling cutting construction testing. The most important part is the holder of the spindle,
without a strong spindle holder it because difficult to produce good quality products. This project
develops a CNC machine in combination with a computer. The fabricated prototype CNC milling
machine with an easy interface that can interpret standard G-M codes. The fabricated machine router
was tested and calibrated to determine its accuracy in different position modes for surface flatness,
axes perpendicularity, and several geometric accuracies such as positioning, straightness under
specific tool paths, and feed rate. The purpose of this project is to develop a low-cost project portable
CNC milling machine. It can be transported using minimum manpower, easily handled and suitable
for small industry. AC power supply is used and sent to the noise filter to reduce signal interference
before sent to the stepper motor to allow axes X, Y and Z move. CNC machine structure movement is
controlled by the DC stepper motor. For example, when DC stepper motor gets signal, it was sent to
the gear box and turn the lead screw that connect with each drivers X, Y and Z through the bearing.
Then, the driver X, Y and Z moving to start cutting process according to the computer instruction
until the cutting done.
Keywords— CNC milling machine, Stepper motor, Spindle motor, SMPS power supply, Nema17
stepper motor, Microcontroller, Lead screw.
 Acknowledgments

I express my deepest gratitude towards my guide Mr. Prasenjit swain for her constant
help and encouragement throughout the project work. I have been fortunate to have a guide who gave
me the freedom to explore on my own and at the same time helped me plan the project with timely
reviews and constructive comments, suggestions wherever required. A big thanks to her for having
faith in me throughout the project and helping me walk through the new avenues of research papers
and publications.
I would like to thank Prof. Azmeera Balu, for the continuous support and encouragement he
extended through the enthusiastic discussions he used to have very often with us and the insightful
thoughts and ideas he used to share. I also take this opportunity to thanks all those teachers, staff and
colleagues who have constantly helped me grow, learn, and mature both personally and
professionally throughout the process.
I would also like to acknowledge with much appreciation the crucial role of the staff in mechanical
laboratory, who gave me a permission to use the lab equipment and also the machine and to design the
drawing and giving a permission to use all the necessary tools in the laboratory.
Many thanks go to the all lecturer and supervisors who have given them full effort in guiding the team
in achieving the goal as well as their encouragement to maintain our progress in track. My profound
thanks go to all classmates, especially to my friends for spending their time in helping and giving
support whenever i need it in fabricating my project.
 TABLE OF CONTENTS

Certificate...........................................................................................................
Abstract.............................................................................................................
iii
Acknowledgments..........................................................................................
iv
List of Figures.................................................................................................
vii

1Introduction....................................................................................................
1
1.1 Objective.......................................................................................................
2
1.2 Methodology................................................................................................
3
1.3 Problem statement......................................................................................
4
1.4 Project scope.................................................................................................
5
1.5 Block diagram...............................................................................................
6
1.6Woking principle...........................................................................................
7
1.7 Hardware components................................................................................
8

2 Design and Fabrication..............................................................................

9
2.1 Design of CNC machine..............................................................................
10
2.2 Selection of material ..................................................................................
11
2.3 Fabrication..................................................................................................
12
2.4 Assembly....................................................................................................
13
2.5 Electronic system.......................................................................................
14
2.6
2.7 ....................................................................................................................
16
2.8 CAD Model.................................................................................................
17
2.9 3D Parts assembly
18

3 Results and Conclusions.........................................................................

3.1Result...........................................................................................................

3.2 Advantages & Disadvantages...................................................................21

3.3 Applications..............................................................................................22

3.4Conclusions...............................................................................................23

3.5 Future scope............................................................................................24

4 Bibliography..........................................................................................25

4.1References...............................................................................................26
 INTRODUCTION
Computer Numerical Control (CNC) is a kind of machine-controlled automatically with the aid of a
computer. The introduction of CNC machines changed the manufacturing industry radically. Complex
shapes and contours can be easily machined from 3-D structures with minimum human intervention and
high precision. The use of CNC machines also reduces the steps in manufacturing process drastically
ensuring consistency and quality of product. CNC automation not only reduces the frequency of errors
and also allows flexibility. In the current work, a 3-axis portable CNC milling machine is fabricated that
performs operations like drilling and milling on wooden workpieces. Parts are automatically programmed
to operate according to the series of events set by the user to create a product of the required shape and
size. The portable CNC milling machine is specially designed and used in classrooms, offices, or
laboratories to help students improve their practical skills. In addition, tabletop CNC machines can still
process products with high precision. Using small machines for production brings many advantages,
saving space and electricity, less vibration, reduced noise, high flexibility, and easily relocated. The CNC
machine is fabricated using wood, metal MDF sheets, which are dimensionally strong and stable ensuring
that drilling and milling operations can be performed with quality and precision. All the parts used are
fabricated and assembled by means of suitable operations like welding, drilling, cutting etc. Different
electronic devices like stepper motors, motor drivers, CNC shield, Arduino and a computer make the
machine functional to perform different operations based on the codes streamed to the machine. The main
aims of the present work are the development, analysis, manufacture, and assessment of a cost-effective,
easy-to-use, flexible, small-scale prototype 3-axis vertical CNC laboratory milling machine developed,
which was developed for student experiments in CNC and CAD/CAM programming areas. The machine
produced must have a simple interface, be easy to use, receive the common G-codec, have low power
consumption, and be safe and durable. Prototypes produced have been calibrated and self-tested to meet
industry standards.

LITERATURE REVIEW
For several years, rigorous research has been conducted in the area of CNC milling from diverse
perspectives (Paulo, Rogério and Maria,2010). Some investigators seem to contribute to the expansion of
the frontier of CNC milling knowledge by focusing on system performance improvement tools such as
sensors (Sergej .N.Gregoriev, Georgi .M. Martinov, 2016), neura land adaptive networks as well as fuzzy
controllers (Phyo Wai Lin, 2018). Others applied optimization techniques to achieve their goals in CNC
milling research (Rajendra rajput et al(2016),). Still, others have focused on different aspects such as
hardenability ( El-bestawi et al.,1997), nano surface generation (X. Xu, Y. Li, J.Sun and S. Wang), new
material study (Sharmanet al., 2001), free-from surface studies (Terrier etal., 2004), carbon steels
(Rajendra rajput et al(2016),) and tool life (Sergej .N. Gregoriev,Georgi .M. Martinov, 2016), thus the
paragraphs follow contain a comprehensive review of existing studies in the literature in its
disicivemodes, covering the various contributions of the authors till date. The research paper by
Paulo,Rogério and Maria, 2010, studied optimization of CNC milling process parameters using PCA-
based Taguchi method that had 35 served the purpose of optimization but not simultaneous optimization
of surface roughness and the material removal rate in the study. S.W. Jang had given the outline of the
soft material milling parameters in their study on optimization of CNC end-milling of UNS C34000
medium-leaded brass with multiple-surface roughness characteristics. A single-response study provided
base in determining the parameters that were studied. The case studies conducted at the laboratory have
prompted for the real-time studies and to find the solution for the manufacturing firms around the place.
Phyo WaiLin, 2018 analyzed the effect of the length and diameter of work piece, depth-of-cut and feed
while the cutting speed, which is an important machining parameter, was kept constant. Taguchi method
was used in this work in order to obtain more reliable and optimum results. Phyo Wai Lin, 2018 criticized
the excessive use of high-speed milling for precision machining of aluminum and magnesium and more
frequently used results in high quality of the surface and shorter machining times by omitting grinding.
Paulo, Rogério and Maria, 2010 highlighted the optimization of the surface roughness when milling
aluminum alloys (AA6061-T6) with carbide coated inserts using response surface method (RSM) and
Radian Basis Function Network (RBFN) to predict thrust force and surface roughness. Sutraman,
Haryono EdiHermawan, Sarmidi brought out the influence of cutter geometry and cutting parameters
during end-milling on the surface texture of aluminum-alloy 5083 that was experimentally investigated
using Taguchi L18 standard orthogonal array. X. Xu, Y. Li, J. Sun and S. Wang presented the fact that the
extensive research has been conducted in the past on tool flank wear and crater wear in high-speed
machining by investigating the effect of tool edge wear on the cutting forces and vibrations in 3D high-
speed finish turning of nickel-based super alloy Inconel 718. Paulo,Rogério and Maria compiled the case
study of high-speed milling of titanium alloys and provided base for different metallurgical and
machining conditions to be taken into account for 36 the study. The case study of titanium-based alloys
were conducted for the high-speed milling process for sets of input parameters with moderate cutting
speeds and feed rate to get better material removal of aircraft materials.

OBJECTIVE
The idea behind fabrication of low-cost CNC Milling Machine is to full fill the demand of CNC machines
from small scale to large scale industries with optimized low cost. A major new development in computer
technology is the availability of low-cost open-source hardware, such as the Arduino microcontroller. An
advantage of open-source hardware is that a wide variety of ready-to-use software is low-cost interfaces
and accessories such as Arduino shields are also available. However, for the development of low-cost
models of CNC machines, such tools may be quite adequate from the viewpoint of machine control. In
this project, the development of a prototype 3-axis CNC Milling Machine using Arduino-based control
system is presented with the following specification.
• Low cost
• Easily operable
• Easy interface
• Flexible
• Low power consumption

METHODOLOGY

The start of the flow work is to understand the fundamental of the portable CNC milling machine. After
doing some research and Study about the portable CNC milling machine, the next step that is needed to
do is design the machine according to the Understanding of the portable CNC milling machine concept.
The designing of the machine including with the wiring connection and the software that is used to
generate the program. Develop the machine base of the design that has been drawn.

PROBLEM STATEMENT

Since, thousand years ago, human tried to find ways to make their work easier. Thus, variety of
techniques and inventions are created to reduce the human work. Nowadays, CNC milling Machine is
most popular in manufacturing sector. To reduce the burden on the people, portable CNC Milling
machine this is the best option because it can be removed easily, saving time, and reducing the use of
space. CNC milling machine is an especially important technology in the manufacturing industry
nowadays. But there are some problems that arise among industrial developers, because the existing
milling machine is compatible with a huge industry only. While for small developers, the problem is CNC
milling machines available now have a large size, heavy and difficult to control. This problem is not
suitable for small industry. The solution is to design and fabricate a model of portable milling machine.
Operating Portable CNC milling machine with low cost and simply in design will be good news for the
developers of small-scale industries.

PROJECT SCOPE

 To produce a vertical portable CNC milling machine.

 Should be operating as milling machine process.
 Should be used G-code to construction the milling cutting testing.
 Used Universal G-code sender software as machine interface.
 To produce a portable CNC milling machine that suitable for small industry.
 Machine testing material used wood and the tool bit from High-Speed Steel (HSS).

OVERVIEW OF THE PROJECT

This project is to develop a model of portable CNC Milling machine that can be moved with minimum
handling.

RESEARCH METHOD

The first step in the operation of CNC machine was calibrating the tool, it was aimed to know whether
the stepper motor and any other system were working according to the program that has been
configured. Followed by setting the starting position of the spindle drill on the CNC machine using
Universal G-code Sender software both automatically and manually by hand spinning. Spindle drill speed
can be set up to a maximum speed of 12000 rpm (rotation per minute). After the CNC machine is
calibrated, the design with the *G-code extension format was uploaded using Universal G- code Sender
to Arduino Uno with serial communication. The microcontroller will read the data as a command and
provide logic to the A4988 motor driver. The data received by the motor driver was used to drive 4 Nema
23 X, Y and Z axis stepper motors, so that a pattern will be formed on the object.

MATERIALS AND METHODS

Design overview of CNC vertical milling machine: -

The CNC vertical milling machine is consisting of X axis for arm movement, Y axis for table movements
and a third Z axis for the spindle cutter linear drive movement, base, and frame. The complete control
unit of the machine consists of the CNC control board and the computer. The accurate rotations are
providing by using stepper motors. The CNC milling machine mainly consists of the mechanical
components (includes the structure, i.e., the base, support structure, lead screws, beams, bearing, etc.),
the electrical system (consists of the motor, motor control unit, interfacing, and power unit) and the
control or computing system to positions the tip of the milling cutter at the required position. The
selection of the motion control system and the linear motion components accomplished by linear guide
rod and drive screws is an important part of the prototype milling machine design. The screws can be
driven by some motors using an open or a closed loop control system. The structure of the CNC machine
consists of the mechanical, drive, measuring, and control systems. The kinematic modules for the
functional systems (supports, stands, and bearing support system) and the drive systems for leading
(sliding and roller guides) and measuring systems for circular and linear movement are built in the
structure. The module of the main spindle consists of several essential functional parts (the spindle
shaft, the housing, axially spaced roller bearings, electric drive motor, internal cooling system, and
system for clamping and releasing tools. The primary design considerations for building a CNC milling
machine are:
The maximum work piece size (maximum travel along the axis) is selected as: X = 350, Y = 300
and Z = 160 mm.

HARDWARE COMPONENTS
1. Lead screw
A lead screw is a type of mechanical screw that converts rotational motion into linear motion. It
consists of a threaded shaft (the screw) and a mating nut, with the screw typically having a larger
pitch than other types of screws. Lead screws are commonly used in various applications where
precise linear motion is required, such as in CNC machines, 3D printers, robotics, and automation
systems.

2. Guide rod
In CNC (Computer Numerical Control) machines, guide rods, also known as linear guide rods or
linear shafts, are critical components used to provide linear motion guidance and support to
various moving parts, such as the tool head, cutting spindle, or workpiece table. These guide rods
play a crucial role in ensuring precise and smooth movement along a specific axis (typically X,
Y, or Z) within the CNC machine.

3. Linear bearing
LM8UU bearings find extensive use in CNC milling machines, where they support and guide the
movement of various components, such as the cutting tool, spindle, or workpiece table, along the
X, Y, or Z axes. These bearings are prized for their high precision, reliability, and relatively low
cost, making them suitable for both hobbyist and industrial-grade CNC systems.
 4. Circular bearing
The circular bearing with an inner diameter (ID) of 8mm, an outer diameter (OD) of 25mm, and a
height (H) of 10mm, is likely a type of radial ball bearing commonly used in CNC milling
machines which support the lead screw and provide a smooth rotation.

5. Shaft coupler
A shaft coupler, also known simply as a coupling, is a device used in CNC (Computer Numerical
Control) machines to connect two shafts together for the purpose of transmitting power and
motion between them. It connects stepper motor shaft to lead screw to transfer the motion
between them in each axis like (X, Y, Z) axis.

ELECTRONIC SYSTEM

The electronics system is responsible for generating a control signal to the stepper motors that guide the
motion of the tool path in each axis or direction. The electronics system contains the power supply, the
microcontroller board, and the stepper motor driver board. The power supply converts the AC
voltage to DC voltage and supplies required voltages to the corresponding devices. The microcontroller
board receives 12V and the stepper motor board also receives 12V. The 3-axis CNC driver
microcontroller development board type Kit TB6560 is chosen here to control the motion of the system. It
is the brain of the CNC system which receives the commands from the software system from the
computer connected through the USB serial port. The Kit TB6560 board is flashed with the GCODE
interpreter code which was written in the C language, which is responsible for generating the control
signal for the corresponding command signal from the computer system to the stepper motors, which
directly controls the motion of the tool path, which is carried away through output pins connected to the
stepper motor drives according to the firmware code in the microcontroller. The stepper motor driver
board receives the control signal from the microcontroller board to the terminals PULSE and DIR, which
generates the corresponding digital pulse signals for three stepper motors to control the rotation of the
motor.
The electronics circuit wiring of the various components of the electronics system is illustrated in Figure
below, with the final electronic board components. The microcontroller board is connected to the
computer system through the USB serial port. The stepper motor driver board terminals PULSE and DIR
of each Board are connected to the microcontroller terminals from 2 to 7 pins (2 terminals for each axis
stepper motor driver). Terminals of the stepper motor driver board are connected to the 3-lead stepper
motor directly. For the software and coding system, the designer generally uses a CAD/CAM program or
programs on a computer. The output of this program, which is a part program and is often in “G-code” is
transferred (by a network or perhaps floppy disc) to the machine controller, which is responsible for
interpreting the part program to control the tool that will cut the workpiece. The signals from the machine
controller are amplified by the drives so that they are powerful enough and suitably timed to operate the
motors.

ELECTRONIC COMPONENTS

1. SMPS
 2. Arduino Uno
3. CNC Shield
4. A4988 Stepper motor driver
5. Limit switches
6. Nima-17 Stepper motors
7. 12v DC spindle motor

ARDUINO UNO
Arduino is a software company, project, and user community that designs and microcontroller- based kits
for building digital devices and interactive objects that can sense and control physical devices. It has 14
digital input/output pins (of which 6can be used as PWM outputs), 6 analog inputs, a USB connection, a
power jack, a reset button and more. It contains everything needed to support the microcontroller; simply
connect it to a computer with a USB cable or power it with AC-to-DC adapter or battery to get started.
There are many varieties of Arduino boards that can be used for different purposes. Some boards look a
bit different from the one below, but most Arduinos have the majority of these components in common.

WORK TABLE

The worktable is made up of MDF wood material. At the backside of worktable ball bearing is fixed
through which guide rods for Y-axis slides. During Y-axis motion the worktable itself moves.
STEPPER MOTOR

A stepper motor or step motor or stepping motor is a brushless DC electric motor that divides a full
rotation into a number of equal steps. The motor's position can be commanded to move and hold at one of
these steps without any feedback sensor (an open-loop controller), as long as the motor is carefully sized
to the application in respect to torque and speed.

FABRICATION AND ASSEMBLY

Fabrication of CNC milling machine is used low-price milling cutter for the main spindle due to
a low voltage supply and it is possible to use the tools of smaller dimension to machine materials
like wood, aluminum and plastic materials. There are several advantages of using small
machines to produce small sized objects. With a smaller machine size, space is saved. The
energy required to operate the machine is reduced as well. The structure frame of the machine
consumes less amount of material; hence it is less expensive to build. The mechanical system is
assembled with the 3-axis movement by using the linear rod with linear bearings. The stepper
motors are mounted to each axis of movement and coupled through the shaft couplers to each of
the lead screw axes. Each table lead screw was supported by using bearings one at each end. A
total of three bearings are selected with a bore diameter of 8 mm, outer diameter = 25 mm, and
thickness = 10 mm. The linear motion of each axis is carried away smoothly by the linear rod
assembly connected to each axis. The liner sliding blocks consist of the hardened steel linear
guide rod and recirculating ball bearing. The speed of the motion in each axis can be directly
controlled by controlling the speed of the stepper motor, which is an electromechanical device
that converts the required electrical control signals (pulses) into discrete mechanical movements.
The selected stepper motors are a brushless, synchronous electric motor that converts digital
pulses into some shaft rotation of equal steps. This is an open-loop controller, where the motor’s
position can be commanded to move and hold at one of these steps without any feedback sensor.
A three CNC-Kit-TB6560-Driver-Board-3x-Nema-17 stepper-motors-PSU was chosen to drive
the motion of the axes as shown in Figure, with about 4.4 KG-cm holding torque, 1.8-degree step
angle, 6 A rated current, 12 V supply voltage with a weight of 0.35 Kg each.
APPLICATION

This machine can be for practical training on CNC.

This is most suitable for use institutional learning programs.

This machine can be used in small handicraft industry.

It will be more adaptable rather than going directly to heavy machinery.

The portability of a machine can be increased as needed.

CONCLUSION

From this project, we learned the principle of CNC machine. We gained better understanding in the
modes of operation of CNC machine. There is various type of modern CNC machines use in industry. In
the current work, the design, fabrication, assembly, and testing of the electromechanical subsystems of a
low-cost three-axis vertical CNC mill suitable for adoption in undergraduate mechanical engineering
laboratory setting with an easy interface, easily programmable, easily operable, high speed, high
flexibility less power consumption, safe and durable for rapid prototyping machining was achieved. The
fabricated portable CNC is used to perform drilling and milling operations on Wooden pieces
successfully. The results obtained were satisfying. The current CNC machine can be altered to perform
operations on other materials by changing the end tool and work holding device. The CNC milling can be
used for cutting, engraving and marking on plywood, foam board to form 2D and `3D objects. Finally,
better and faster control for more intricate designs should be thought of and implemented. The fabricated
prototype CNC milling machine with an easy interface can interpret standard G-M codes, calibrated, and
self-testing to meet the industrial standard. The fabricated CNC router was tested to determine its
accuracy in different position modes for surface flatness, axes perpendicularity, and several geometric
accuracies such as positioning, straightness by machining a workpiece under a specific tool path and feed
rate. The validation of test results showed an exactable accuracy in alignment, and this indicated a good
fabrication, and assembling implemented the prototype milling machine. After comparison and making
the required improvements in both electrical and mechanical design, the machine is in a position to
milling a complex contour on soft metals with considerable accuracy and speed.

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