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DESIGN AND DEVELOPMENT OF CNC PLOTTER MACHINE

Pradip Patil*1, Pruthviraj Lidhade*2, Sushant Khamkhar*3,
Yashodip Mane*4, Akshay Dhole*5, Suraj Patil*6
*1Facultyof Mechanical Engineering , Annasaheb Dange College of
Engineering and Technology , Ashta-416301, (Maharashtra), India
*2,3,4,5,6Department
of Mechanical Engineering , Annasaheb Dange College of
Engineering and Technology , Ashta-416301, (Maharashtra), India
ABSTRACT
With the advanced technology, demand for Computer Numerical Control (CNC) plotter machines in Educational
Institutions and Laboratories is rapidly rising. The low-cost manufacturing of Printed Circuit Board (PCB) has
become a basic need in electronics laboratories. This project will present a cost-effective model of a CNC plotter
machine that can draw a circuit layout on PCB or different sketches on paper or any other solid surface using a
simple algorithm, some set of open-source software, and available components. At first, the user needs to
convert any image file into G code using Inkscape software and then feed it to the machine using Processing
software or Universal G-code sender. Arduino UNO with a microcontroller named ATmega328P is used as the
control device for this project. The ATmega328P converts G-code into a set of machine language instructions
that are sent to the motor driver of the CNC plotter.
Keywords: Computer Numerical Control, Cost Effective, Algorithm, Arduino UNO, Machine Language
I. INTRODUCTION
The world has become high technology with a lot of things becoming smaller and thinner and fast-
growing development of high technology and manufacturing. All those can be achieved through the machines
that are controlled by computers such as CNC machines. The computer numerical control is an advanced form
of soft automation developed to control the motion and operation of machine tools. The numerical control
machine was invented around in 19th century to reduced workload; it is a method in which the manufacturing
machine uses the coded format, digits, letters.
Today’s industry requires producing large quantity and quality products with low production and
installation cost. These tasks can be easily completed by machines that are controlled by computers to make
work easier with ultra-precision and less human-caused errors. These are commonly known as CNC Machines.
The CNC stands for Computer Numerical Control. Different kinds of CNC machines cover an extremely large
variety. Their numbers are rapidly increasing, as technology development advances. The fabrication of a low-
cost CNC machine is used to reduce cost and complexity.
This project deals with drawing circuits on PCB and drawing on other materials like wood, paper, and
fiber. Low-cost manufacturing of Printed Circuit Board (PCB) has become a basic need of small scale electronic
industries and electronics laboratories. To satisfy this need there is several machines and mechanisms are
available in the market. But these machines have some drawbacks like some machines are very must costly,
some machines are very much complex and some machines are not suitable for small scale applications. The
computer numerical control is an advanced form of soft automation developed to control the motion and
operation of machine tools. The numerical control machine was invented around in 19th century to reduced
workload; it is a method in which the manufacturing machine uses the coded format, digits, and letters.
CNC Machining is a process used in the manufacturing sector that involves the use of computers to
control machine tools. Tools that can be controlled in this manner include lathes, mills, machines, and grinders.
The CNC stands for Computer Numerical Control. Inspiring from this CNC technology and revolutionary change
in the world of digital electronics & Microcontroller, we are presenting here an idea of a CNC pen plotter using
custom-built PLC. The idea behind this project is to make a small CNC machine that can draw images or pictures
on the surface which can be a paper or anything. It uses three stepper motors as linear actuators on each axis X,
Y & Z. While printing/drawing, the proper synchronization of this entire three-axis i.e. stepper motors, is the
most challenging task. At present, the data to draw is given programmatically i.e. hardcoded in a program in
binary format. A pen touches the surface & prints the pixel for logic 1 and lifts in the air for logic zero & actuator
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changes its position for next commands execution. As in plan, it can access the G-Code directly From supporting
software like Inkscape. The presented plotter is a one-dimensional 1D plotter. The idea behind this technique is
to design PCB based on a low-cost CNC system the lower cost is achieved by incorporating features of PC with
ATMEGA 328 controller in an Arduino. We have used a G code for whole system operation G code is nothing but
a language in which people tell computerized machine tools ‘How to make something’. The How is defined by
instructions on where to move & how fast to move.

Fig No 1:- Actual Set up For CNC Plotting Machine

A Plotter is a special type of printer that uses a pen to draw images on solid surfaces. In Computer
Numeric Control (CNC), the microprocessor is used which is capable of processing logical instructions
interfaced with a computer. The logical instructions are provided by using a computer in the form of code or
text or image which is then transformed into a machine language by the microprocessor to be executed by the
machine. A CNC plotter machine is a 3D controlled 2D plotting machine that uses a pen to draw text or image on
any given solid surface. It can be used for purposes such as PCB Design, logo design, etc. This technique is based
on the CNC plotter machine. With the increasing demand for the use of CNC plotters in universities and
laboratories, a cheap and less complex design is an absolute need. The parts used for the plotter in our project
are easily available at a very low price and spare parts are also used. The construction is very simple and
robust.
II. METHODOLOGY
Selection of Mechanism for CNC Plotting Machine
After the Study of all the mechanism for linear motion and finally lead Screw mechanism is selected
because it will fulfill all the requirement of the plotting machine and lead screw has a number of advantages
including a relatively high load carrying capacity. They are also compact and simple to design into a system
with a minimum number of parts. The motion is also generally smooth and quiet and requires little
maintenance.
A lead screw is a screw which translates rotary motion into linear motion. Normally used as the driving
mechanism in horizontal or vertically driven applications aided by linear guides for supports. They are
described by diameter and pitch or lead. The pitch or lead is the amount of travel you get or distance the nut
travels along the screw for every complete revolution. They can be operated manually or motorized. A lead
screw, also known as a power screw, is a threaded rod or bar that translates rotational motion into linear
motion. When it comes to translating the rotary motion of a motor to linear motion, there are many different
ways of accomplishing this task. Often times in the world of motion control, the battle between the different
methods and technologies can get quite contentious. However, as a rule, it’s best to remember that specific
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applications are better for some technologies than others, and as always, cost and product life time are also
critical factors in determining which technology to use in a given application. Lead screws generate sliding
rather than rolling friction between a nut and the screw. Consequently, higher friction means a lower overall
efficiency. And efficiency, when talking about lead screws, is simply the ability to covert torque to thrust while
minimizing mechanical losses.
A lead screw has a number of advantages including a relatively high load carrying capacity. They are
also compact and simple to design into a system with a minimal number of parts. The motion is also generally
smooth and quiet and requires little maintenance. Lead screws also work well in wash-down environments
because the materials used and the lubricant-free operation allows total immersion in water or other fluids.

Fig No 2:- Lead Screw Mechanism

Design and Selection of Components
1) Selection of lead screw and Nut:
For selection of Lead Screw and Nut required following data -:
Mass of the table = 500 gm.
Mass of the work = 300 gm.
Stroke length = 400 mm
Maximum speed = 0.0167 m/sec
Position accuracy = 0.30 mm/ 1000 mm
Position accuracy repeatability = 10 /mm
Driving motor = Stepper motor
• Selecting lead angle accuracy
To achieve position accuracy of 0.3 mm / 1000 mm
+0.3 +0.9
=
1000 3000

Therefore lead accuracy must be ± 0.09 mm at 300 or higher

Therefore select as the following as the grade of lead screw table no 1
• Selection of screw shaft length
Table length of screw = Stroke length + Nut length + Bearing 1 + Coupling to attach
Motor + Bearing 2
= 400 + 7 mm + 12 mm + 7mm+ 50 mm+ 10mm +5 mm + 5mm
= 496 mm ≅ 500 mm
Thus screw length is 500 mm.
• Selection of Pitch :
With driving motor rated rotational speed having 800 rpm and maximum speed 0.0167 m/sec.
The pitch of screw
0.0167∗1000∗60
= = 1.25mm
800

From the formula, we have selected the pitch of 1.25 mm.

• Selection of screw shaft diameter :
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From the lead screw accuracy and pitch (1.25), we have selected screw shaft diameter from table 2
Therefore, Diameter of screw shaft is 8mm.
• Selection of screw shaft support method :
Since the screw shaft has long length of 500mm and having stroke length is 400 mm and operating at
medium speed of 0.0167 m/sec.
Therefore shaft is supported with simply supported on both the end and total distance between to supporting
bearing is 460 mm.
Maximum rotational speed
𝑣∗60∗103
Nmax =
𝑃ℎ
0.0167∗60∗103
=
1.25
= 800 rpm
From above calculations we have selected lead screw shaft having specifications has -
major diameter = 8 mm
Pitch = 1.25mm
Lead screw shaft lead angle =3˚⃘ 46ʹ
Allowable Dynamic thrust = 1470 N
Nut type is = Brass
⍺ = 9.8
Coefficient of friction = 0.21
• Check the selection of Nut
Contact Pressure P
fs
P= *⍺ ………. fs = Axial load (N)
fa
fa = Allowable Dynamic thrust (N)
8
P= * 9.8
1470

P = 0.053 N/mm2

Speed (V in m/min)
𝜋∗𝑑∗𝑛
V= 10−3 d2 = diameter of screw
cos 𝑑

n = screw revolution
d = screw lead angle

𝜋∗8∗800
V= 10−3
𝑐𝑜𝑠3˚⃘ 46ʹ

V= 20.14971928 m/min

Graph 1- PV value Graph

From the contact pressure (P) and speed (v) plot on the graph and check limiting of the PV from the
permissible limit.(from graph 1)
• Screw efficiency
1−μ∗tan (d)
n= μ = dynamic friction coefficient
1+μ∗tan (d)

d = screw shaft lead angle

1−0.21∗tan (3˚⃘ 46ʹ )
n= = 0.24 =24%
1+0.21∗tan (3˚⃘ 46ʹ )

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• Load torque (N.cm)

𝑓𝑠∗𝑅
T= fs = axial load (N)
2𝜋𝑛
R = lead = 4*P =5mm
n = screw efficiency

8∗0.5
T=
2𝜋∗0.24

T = 2.6524 N-cm
• Safe Running speed for lead screw
Every lead screw has a rotational speed limit. This is the point at which the rotational speed sets up heavy
vibration. The critical point is located on the graph 2.
The critical speed limit can be found by locating the point at which the speed of rotation (horizontal
lines) intersects with unsupported shaft length (vertical lines).
It is recommended that the lead screw can be operate at 80% of the critical speed limit value
Maximum bearing distance = 460 mm
Diameter of lead screw = 8 mm
Operating speed should be less than, 900 * 0.80 = 720 rpm
Operating safe speed is below = 720 rpm

Table no 1:-Lead angle Accuracy

Graph no 1 -: PV graph

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Table No 2-: Standard Diameter for Screw Shaft

Graph no 2 -:Maximum Safe Speed

2) Selection of Motor
Lead screw
Diameter = d = 8 mm = 0.314 inch
Pitch =P = 1.25 mm = 0.04924 inch= 20 threads/inch
Lead= L = 4*P = 0.1968 inch
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Coefficient of friction =0.21
Efficiency of screw = 0.24
Length = l= 500mm = 19.68 inch
Critical speed = 800 rpm
Accelerating time = 75 milliseconds = 0.075 second
Table load = 600 gm. = 1.322 lbs.
Carrier and Nut load = 200 gm. =0.4409 lbs.
Total load = 800 gm. = 1.76 lbs.

Ttotal = Tfriction + Tacceleration

Ttotal = Total torque
Tacc = accelerating torque
T friction =friction torque

Tfriction = F/2π Pe
Where
F= friction force in
P = Pitch in rev / inch
e = lead screw efficiency
F = μs*w
Where
μs =coefficient of friction
W = load
F = 0.21 * 1. 76 = 0.3696 lbs
F = 0.3696 * 16 = 5.9136 oz

Tfriction = 5.9136/2π*20*0.24 =0.1960 oz-inch

1 𝜔
𝑇Accl = (𝜏load + 𝜏leadscrew + 𝜏motor + 𝜏coupling)
𝑔 𝑡
𝜋∗𝑑∗𝑁 𝜋∗0.314∗800
𝜔 = 2𝜋𝑝𝑣 𝑣= = = 13.15 inch/sec
60 60
𝜔 = 2𝜋 ∗ 20 ∗ 13.15
𝜔 = 1652.4777 𝑟𝑎𝑑/𝑠
𝑊 1.76
𝜏Load = = = 1.14 * 10-4 oz-inch2
(2𝜋𝑝)2 (2𝜋∗20)2
𝜋∗𝐿∗𝜌∗ 𝑅 4 𝜋∗19.68∗4.48∗ (0.157)4
𝜏Leadscrew = = = 0.08414 oz-inch2
2 2

𝜏Motor = 0.3717 oz-inch2

𝑀𝑅 2 16.821∗ 0.952
𝜏Coupling = = = 7.5855 gm.cm2=0.03550 oz-inch2
2 2

𝑀 = 𝜌∗𝑉
𝑉 = 𝜋 ∗ 𝑅2 ∗ ℎ = 𝜋 ∗ 0.952 ∗ 2.2 = 6.23
𝑀 = 2.7 ∗ 6.23 = 16.821 gm
1 1652.4777
𝑇Accl = (1.14 * 10-4 +0.08414 + 0.3717 + 0.3553 )
3.86 0.075

= 28.0502 oz-inch
𝑇total = 𝑇accl + Friction = 28.0502 + 0.1960 = 28.25 oz-inch
• For selection of stepper motor
Motor Torque = Total torque * Factor of Safety

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Factor of Safety = 1.5
Motor Torque = 28.25 * 1.5 = 43.375 oz- in
Therefore Convert 43.375 oz-inch to N.cm =30.6294 N.cm
For this torque rating Nema 17 stepper motor is selected. This motor has torque 42 N.cm
3) Selection of Bearing
Total axial force acting:
Torque required for the system is 30.6294 Nm
Now
Total thrust force acting
2𝜋∗𝑒 𝑇𝑟𝑒𝑞 2𝜋∗0.24∗30.6294
(FT) = =
𝜌 0.125

(FT) = 369.50 N
Now
Selection of bearing:
1. Equivalent dynamic load (P)= Fr * Y Fa
Here No any radial load is acting because all the radial load is taken & Y =1 & Fa = 369.50 N
2. Select deep groove ball bearing
3. Bearing life (expected bearing life is 1000 hrs)
60∗𝑛∗𝐿10ℎ
L10 =
106
60∗800∗1000
L10 =
106
L10= 480 million revolution
𝑐
4. Dynamic load=L10 = ( )𝑃
𝑝
𝑐
480 = ( 3
)
369.50
C= 480 * 369.50
1/3

C = 2893N=650 lbs
From the dynamic load bearing number 608 is selected.
Specification of 608 bearing
Bore diameter = 8 mm
OD = 22 mm
Width = 7 mm
Min Champer = 0.30
Bearing No = 608ZZ
Dynamic load carrying capacity = 750 lbs.
Static load carrying capacity = 315 lbs.
4) Design of Guide Ways
In the CNC plotting machine all the radial load of carrier is transfer only on the linear guide ways. So to
select the linear guide ways which should not be bending at centrally when load is applied. If the bending
happens then the plotting machine has problems in It reduces the Accuracy of machine.
It has increase in friction between linear guide ways and carrier. Due to bending operation is getting
very much noisy and reduces the life of component. That’s why the linear guiding rod has less bending along
the load.
For the machine we select guiding rod which has 8 mm diameter and 500 mm length and its material
is stainless steel.
So to check whether this rod sustain the load with very less bending in the rod and the safety of rod.
Let,
Rod has diameter 8mm and length 500 mm and supported by simply supported champ.
Let us draw the grid in the form of simply supported beam with UDL load.
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Given
D = 8 mm
L = 500 mm
W = 0.16 N/mm
Span = 50 mm
Esteel = 180 GPa
Sol: To find out bending of beam
Flexural equation is given by
m 6b E
= =
I y R

Where,
m = Bending moment (N.mm)
I = moment of inertia for beam cross section (mm4)
y = distance of layer subjected to bending from the neutral axis
(mm)
E = modulus of elasticity N/mm2
R = radius of curvature of beam (mm)
From formula
m 6b
= ------ (1)
I y
m
6b = *y
I

The bending moment for the simply supported beam with udl is
𝑊𝑙2 016∗5002
m= =
8 8
m = 5 * 103 N.mm
Now
Moment of inertia of circular section is given by
𝜋 𝜋
I= 𝐷4 = ∗ (8)4
64 64

I = 201 .06 mm4

And
𝐷 8
y = = = 4mm
2 2
Put all values in equation (1)
m 6b
=
I y
5 ∗ 103 6b
=
201 .06 4

6b =99.47 N/mm2
• Stress distribution of beam
Now find out the radius of curvature of beam
m E
= ------ (2)
I R
5 ∗ 103 180∗ 103
=
201 .06 𝑅

R = 7238.16 mm
So the radius of curvature is very much high so bending of the beam is very less therefore selected size
for the guiding rod is safe for use.

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III. MODELING

CNC plotting machine has control circuit diagram is shown on above fig. In the control circuit shows as
all the connections and components that are required to run the plotting machine we used Arduino as
controlling unit and to attach all necessary components for controlling the motion. To interface stepper motor
and servo motor. To arduino controller interface we required motor driver A4988 stepper motor driver to
control the stepper motor. All stepper motor and motor drivers are attached and interfaced to arduino with the
help of CNC shield. Basically CNC shield has some features to control component of CNC machine like actuators,
sensors and spindle and trigging signal for coolant ON & OFF. And also this CNC shield is used to power supply
the stepper motor.
In the CNC plotting machine firstly we have one design or part model on the designing software called
inkscape and this design & drawing is converted to a ‘G’ code file. This file is send to arduino with the help of
universal ‘G’ code sender software this software sends all the ‘G’ code & ‘M’ code to arduino after all that
arduino has processing on the ‘G’ codes & ‘M’ codes .According to ‘G’ code commands. Arduino will send the
particular signal to the motor driver and motor driver control the stepper motor axis with particular signals.
According to particular motor running the axis of that motor start to draw. Similarly to pointer should
start to draw. Similarly the pointer should get up & down this operation of pointer up & down is controlled by
commands of m3 & m5. The m3 has upward and m5 for downward the pointer. With the use of all the operation
particular drawing is made by the machine and we can give the command through the ‘G’ code sender for
manual operation.
IV. RESULTS AND DISCUSSION
This project is designed with a very simple construction scheme and can be carried anywhere
without many efforts. A very simple algorithm is implemented which can handle any type of
modifications made within the machine without rewriting it. Though the circuit is very complicated to
handle so, it is preferred to create a compact one i.e. by minimizing the jumper wires, can easily be
stick to the back of the machine. It consumes low power and works with precision which could be altered
accordingly by the user within the C code. In addition to the personal use for small-scale application in
educational institutes, this project can be resourceful to all generations of the society.
In the project we are Plotted Text file and take the Results of plotting Machine at a time of Plotting.so
For Plotting the text firstly we are converted Original Text File into G code file and then we are Plotted.at a time
of Plotting Process we check the Commands that are given to the plotting machine by Controller.
Original Text-:

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Plotted text-:

V. CONCLUSION
In this work, we got familiar with one of the famous industrial technology which is Computer Numerical
Control. After a hard work for creating a working CNC prototype we have gained skills in electronics and
software as well as programming since we have built the mechanical part by ourselves. In electrical part, we
have studied the stepper motor mechanism, and its control theory, we used the A4988 stepper motor driver.
These motors were very helpful in our project since they are easy to use because they are controlled with open
loop control system .Beside that, we acquired the knowledge of the programming language to develop
Graphical User Interface applications that runs under OS to stream the g-code file to the microcontroller.
VI. REFERENCES
[1] Venkata Krishna Pabolu, Sri K.N.H Srinivasas, “Design and Implementation of a Three-Dimensional CNC
Machine”, IJCSE, Vol. 2,pp.2567 -2570 No. 08, 2010.
[2] Kajal J. Madekar, Kranti R, Nanaware, Pooja R. Phadtare, Vikas S. Mane, “Automatic mini CNC Machine for
PCB drawing and drilling”, IRJET, Vol. 3,PP 1106-1110 Issue-2, 2016.
[3] Mohammad Kamruzzaman Khan Prince, Muhsi-Al- Mukaddem Ansary, Abu Shafwan Mondol.
Implementation of a Low-cost CNC Plotter Using Spare Parts, International Journal of Engineering Trends
and Technology, 43(6), 2017, pp. 333 –339.
[4] Anil Kumar, A., Sai Krishna, K., Sai Reddy, R.B.G. and Shakti Prasad, V. CNC Machine for Drawing, B.Tech.
Project Report, MLR Institute of Technology, 2017.pp. 801–808.
[5] Shani Ranjan, Mani Rani, Shweta Ranjan, Dr. Manmohan Singh. Design And Implementation of low-cost 2D
plotter Computer Numeric Control(CNC) Machine. May 2018 pp.99-101.
[6] Lakshmi pathi Yerra, K. Chinnamaddaiah and Subramanyam B, P. Ravi kanth Raju. Development of an open
type CNC system for a 3-axis nicy=rocnc machine, International Journal of MechanicalEngineering and
Technology (IJMET). Volume 8,Issue 6, June 2017, pp. 463-470.
[7] Dr M Shiva kumar, Stafford Michahail, Ankitha Tantry H, Bhawana C K, Kavana H, Kavya V Rao, “Robotic 2D
Plotter”, International Journal of Engineering and Innovative Technology (IJEIT) Volume 3, Issue 10,
pp.300-303 April 2014.
[8] Sundar Pandian ,Raj Pandian.“Low cost build your own three axis CNC mill prototype”, International
Journal of Mechanical Engineering and Robotics, ISSN 2321-5747,vol,2 issue1,2014 pp.6-11.
[9] Paulo Augusto Sherring da Rocha Junior, Roge‟rio Diogne de Silva e Souza, Maria Emilia de Lima Tostes,
“Prototype CNC Machine Design”,IEEE,2010.
[10] S Sherring da Rocha Jr., P.A., Souza, R.D.S. and Emilia de Lima Tostes, M. Prototype CNC machine design,
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