PCB Printing and Drilling Machine

with Efficient Path Planning

Authors

Abdul Salam Aslam 2015-MC-146

Hussain Ahmad 2015-MC-154

Muhammad Ahmad 2015-MC-162

Muhammad Arham 2015-MC-186

Project Advisor:

Engr. Umar Siddique Virk

DEPARTMENT OF MECHATRONICS & CONTROL ENGINEERING

FACULTY OF MECHAINCAL, MECHATRONICS & MANUFACTURING

ENGINEERING

UNIVERSITY OF ENGINEERING AND TECHNOLOGY LAHORE,

FAISALABAD CAMPUS

1
 PCB Printing and Drilling Machine
with Efficient Path Planning
Abdul Salam Aslam 2015-MC-146

Hussain Ahmad 2015-MC-154

Muhammad Ahmad 2015-MC-162

Muhammad Arham 2015-MC-186

A thesis submitted in slanted fulfillment of the responsibility for the

makings of B.Sc. Mechatronics & Control Engineering

Project Advisor:

Engr. Umar Siddique Virk

Co-Advisor:

Engr. Zia-ur-Rehman

Thesis Supervisor’s Signature: _____________________________________

External Examiner’s Signature: _____________________________________

i
 Abstract

Industries of the land status automation in different equipment which consumes an

abundance of second. One of these systems is Cartesian Milling tool which can
wage author production in tender span of dimension. All of the setups in industries
regarding milling machines were manually manufactured by roadworthy indorse
workshops and there was not a single scientific pattern regarding this organization.
It was a high need for designing, business and construct. It was also a great
poorness to automate it by figure software. The fast use of robot-based
mechanization discipline provides convenience in a difference of processes, both
in the face of rising the caliber and abstraction of the production awareness. One
lesson of a manual robot curative of this grouping is a robotic cause with a
Mathematician design identify, which produces 3-axis lengthways occurrence and
which touches the method of production organization which is victimized as a cut
aimed at objects in the form of a PCB target in the PCB manufacture.
Keywords: Cartesian manipulators, robotics, PPP linear motion.

ii
 Undertaking

We certify that research work titled “PCB Printing and Drilling Machine with
Efficient Path Planning” is our own work. The line has not been presented
elsewhere for categorization. Where stuff has been victimized from opposite
sources it has been properly granted / referred.

…………………….... ……………………..

Abdul Salam Aslam Hussain Ahmad

2015-MC-146 2015-MC-154

…………………….... ……………………..

Muhammad Ahmad Muhammad Arham

2015-MC-162 2015-MC-186

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 Acknowledgements

All acclamation and praises are for "Almighty ALLAH". Most Polite, Most Kind,
and Most Eleemosynary. Our primary prize and praises to the preeminent man of
the collection, the Consecrate Oracle Hazrat Muhammad (PBUH) who is
forever, a torch of control, for mankind.

We would similar to convey Parents, Siblings and Friends who kept championship
us up in all the times, both financially and morally.

We would also similar to convey Engr. Umar Siddique Virk whose valuable
suggestions and guidance brought us to point of achievement. This project has
immensely helped us to get exposure to emerging technology of current robotics.
We thank him providing all the necessary help, support and resources 0n this
project

We are thankful to Allah Almighty who provides all the resources of every
openhearted to us, so that we head their proper use for the help of mankind.
All our group members showed inundated obligation and severity toward the send.
Everybody did their break according to the arrangement. This program had never
been completed if anyone of us would have showed need of welfare.

Moreover, we would similar to thank faculty members of Mechatronics and

Control Engineering Section for their endless and expensive validation to excrete
this pass during our final year of degree idea. Furthermore, we would similar to
convey propose lab body for their work and funding to staring this cast.

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PCB Printing and Drilling Machine
with Efficient Path Planning

v
 Table of Contents
Abstract…………………………………………………………………………………....ii
Undertaking……..………………………………………………………………………....iii
Acknowledgement .......................................................................................................... iv
Table of contents…………………………………………………………………………...vi
List of Figures...…………………………………………………………………………….ix
List of Equation.…………………………………………………………………………….x

CHAPTER 1........................................................................................ ............................. 1

1. Background.............................................................................................................. 1
1.1 Introduction.............................................................................................................. 1
1.1.1 As Milling Machine...............................................................................................1
1.1.2 PCB Milling Machine…….……...………………….…………………………...2
1.2 Problem Statement……... ........................................................................................ 2
1.3 Motivation and Objective……... ..............................................................................2
1.4 Pictorial System Overview .......................................................................................3
1.5 Main Features........................................................................................................... 4
1.5.1 3-Axis Linear Motion…………………………………………………………... 4
1.5.2 Lead Screw Mechanism…….……………………….…………………….......... 4
1.5.3 Milling................................................................................................................. 5
1.6 Milling Benefits ....................................................................................................... 5
1.7 Report Outline........................................................................................................... 5
1.8 Background………………………………………………………………………... 6
1.9 Robot Domain……………………………………………………………………... 6
1.10 Milling Domain........................................................................................................ 7
CHAPTER 2……………………………………………………………………………...8
2. Literature………………………………………………………………………….. 8
2.1 Etching……………………………………………………………………………..8

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 2.2 Printing………………………………………………………………………...….9
2.3 CNC Machine………………………………………………………………..…..10
2.4 Efficient Path plaining……………………………………………………….......11
2.4.1 Based control and modeling of CNC Machine………………………............11
2.4.2 System & Method for positioning work-pieces on CNC machines…......….11
2.4.3 Firefly algorithm for path optimization in PCB holes drilling process…......12
2.4.4 Automated PCB Drilling Machine with Efficient Path Planning……......….12
2.5 Simulation tools to study behavior of CNC………………………………….......13
CHAPTER 3 ....................................................................................................................14
3.1 Mechanical Structure .......................................................................................14
3.1.1 Precision rods………………………………………….……….....................14
3.1.2 linear bearings.................................................................................................15
3.1.3 Lead screw ……………………………………………… ……………......16
3.1.4 Radial Ball bearings………..…………………… ………………………...16
3.1.5 Frame…………………………………… …………………………………17
3.1.6 Drill bits………………………… …………………………………………17
3.2 Mechanical Design……………. ……………………………………..…………..18
3.3 Calculations…………….. ………………………………………………………..19
3.3.1 Force Calculations……………..………………………………………...…..19
3.3.2 Torque calculations……………...……………………………………..…....21
3.3.3 Motor selection………………….……………………………......................22
CHAPTER 4..................................................................................... ................................23
4 Software Working...……………………………………...………………….……….23
4.1 INKSCAP………………….……………................................................................23
4.1.1 Working with INKSCAP………..……………………………..…………….23
4.2 G-Cam……………………………………………………………... ………...……23
4.2.1 Working with G-Cam…………………………………………………… …24
4.3 GRBL…………………………………………………….……………….. ………24
4.3.1 Working with GRBL…………………………………………………...…...24
4.4 Hardware Working...……..…………………………………………………..........25

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 4.4.1Arduino………………………………………………………….…………..27
4.4.2CNC Shield…………………………...……………………………………..28
CHAPTER 5..................................................................................... ................................29
5 Experiments and Results...……...………………………...………………….……….29
5.1 Results………………….……………........... ....................................................29
5.1.1 PCB Machine……….………..…………………………...…..………….29
5.1.2Printing And Drilling Area.…………………………….....……………….30
5.1.3Low Price……………………………………………….....……………….30
5.2 Software Configuration………………........... ...................................................31
5.2.1Proteous…………………..…………………………….....……………….31
5.2.2Copper Cam……………....…………………………….....…..…..………33
5.2.3GRBL……………………..…………………………….....………………40
5.3 Machine Quality……………………….............................................................42
CHAPTER 6......................................................................................................................43
6 Conclusion and Future recommendations.………………………...………………….43
6.1 Conclusions…………….……………................................................................43
6.2 Future Recommendations……………................................................................43
Referances….......................................................................................................................45

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 List of Figures

Figure 1.1. Pictorial Diagram ..............................................................................................………3

Figure 1.2. PPP Configuration…… ...................................................................................….…….4
Figure 1.3. Ball Screw…….…… ....................................................................................................4
Figure 1.4 Milling…… ....................................................................................................................5
Figure 1.5 Different types of Robot……………………………………………................…….….6
Figure 1.6 Engraver…………………………………………..……………………………….…...7
Figure 3.1 Precision rods……………………..…………………………………………………..15
Figure 3.2 linear bearings…………………………..………………...…………………………..15
Figure 3.3 Lead Screw………………………………………………………..…………………..16
Figure 3.4 Radial Ball bearings………………………………………….…………………....….17
Figure 3.5 Drill Bit…………………………………………………….…………………...…….18
Figure 3.6 CAD Design…………………………………………………….……………....…….18
Figure 4.1 GRBL………………………………….……………….….…………………….……24
Figure 4.2 Arduino types…...…………….…...………………….………………………………25
Figure 4.3 Arduino Activation of CNC sheet ……………………………….……………………26
Figure 4.4 Arduino…….…...…………….…...………………….………………………………25
Figure 4.5 CNC Shield...…...…………….…...………………….………………………………28
Figure 5.1 Hardware and model manufacturing…….…………….………………………………29
Figure 5.2 Working Area….…………….…...………………….………..………………………30
Figure 5.3 Circuit Diagram…….….......….…...………………….………………………………31
Figure 5.4 Circuit Diagram……………….…...………………….………………………………32
Figure 5.5 Generate Gerber...…………….…...………………….………………………………32
Figure 5.6 Proteus output……...………….…...………………….………………………………33
Figure 5.7 Circuit…….…...…………….…...………………….………………………………...34
Figure 5.8 Offset and origin……………….…...………………….…………………..…………34
Figure 5.9 Tool library.…...…………….…...………………….………………………..………35
Figure 5.10 Active Tool…….…...…………….…...………………….…………………………36
Figure 5.11 Active Contours.…...…………….…...………………….……………………….…37
Figure 5.12 PCB Circuit…...…………….…...………………….………………………..……...37

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Figure 5.13 Drilling Tools…….…………….…...………………….………………………….38
Figure 5.14 Engraving Output Generator.…...………………….……………………………...39
Figure 5.15 Drilling Output Generator………….…...………………….……………………...39
Figure 5.16 GRBL Interface….…………….…...………………….………………………..…40
Figure 5.17 GRBL interface with Circuit.…...………………….……………………………...41
Figure 5.18 Output (1-2) …….…...…………….…...………………….………………………42

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 CHAPTER 1
Introduction

1. Background:
The most important part of Mechatronics and Control Course is to design and realize a robot.
A robot is a gracious ideal of a mechatronic grouping. Most robots integrate software, electronics,
and mechanized designs in a cooperative way (significance that the isolable parts act unitedly in a
specified way that the compounded validity is stronger than the sum of the unintegrated personality
of each one of the components).
Mechanism that is pressurized finished sensors and actuators should be mortal amicable and easily
monitored and pressurized by anthropoid and uninjured. We decide to build a robot that produces
3-d motion performing milling as well as drilling as an application. [1]

1.1 Introduction:

1.1.1 As Milling Machine:

Cartesian Mechanism Cause (CRM) is a 3-degree of freedom robot cause with Cartesian interval as
it utilize enclose. It has been organized and formed for work purposes. The principal cast of CRM
consists of perpendicular collinear prismatic joints that are motivated severally to attain the end
effector orientation. A piece integrated has a discrete Dancer travel (with optical encoders and
mechanism heads collective together) and rotary proposal of the motors is transformed into lineal
motility through a metal screws. A study affianced with a DC-motor is used to engrave the work
piece(PCB). The idea behind this project is to make a small three Axis manipulator which can
engrave PCB sheet, Characters or shapes with help of a drill on PCB. It uses 3 stepper motors as
rectilinear actuators on apiece alliance X, Y and Z. Patch milling, the prim coordination of all this
alignment i.e. dancer motors, is most challenging chore. The X, Y and Z actuators leave be
prefabricated with exalted torque utilized to engrave work piece. The intelligence behindhand the
grouping faculty be AVR ATMEGA 328 supported restrain organization with Arduino
programming construction. Arduino testament perceive the G-Code over program left from the G-

xi
code interpreter & transmitter quality puppet lengthwise on PC and instrument spring the actuation
commands to the stepper motorial human. The Arduino Uno/Mega is a microcontroller board
supported on the ATmega328. The Arduino Uno can state via the USB transferal or with external
cognition render. External superpower can come either from a battery. Put the image in INKSCAP
which changes the identification of image after which it is sent to G-CAM which yields G-codes
feeding them to GRBL and finally to CNC shield disciplined by Arduino. The Arduino can be
programmed with Arduino software exercise is pledged to DC-motor which is affined to Z-axis
using fare. The drill which is attached to the Z-axis acts like a 4th axis. This cut moves according to
the codes which are in actual the positions performing milling.

1.1.2 PCB Milling:

Printed Circuit Board milling is the process in which areas of copper are removed from PCB sheet
to recreate signal traces and structures following the pattern from layout file. It is a process in which
no chemical is used like used in etching process. Therefore, it can be used in lab environment easily
without danger of harmful chemicals.

1.2 Problem Statement:

“We need a robot that can perform 3-d motion accomplishing special task called the Milling
and drilling specifically on PCB sheet.”

So far, the approach on making 3-d devices has grown enormously on different mechanisms like
rack and pinion or lead screw, ball screw etc. Our goal is to achieve a 3-d motion performing milling
as an application but mainly a lab equipment.

1.3 Motivation and Objective:

Multidimensional motions of a single machine performing economical services are the requirements
of modern industry. In modern industries, motions are made to have different applications. The
applications may include car painting, ergonomics, placing objects on specified coordinates, lifting

xii
heavy loads, parts assembly etc. All of these include motion of some kind. Mostly 3-D and 6-D
motions are in use.

On this dissertation, we goal at designing a 3D motion provider. Such an approach would allow 3-
D motion. This 3-D motion is linear (a motion in straight line). All the joints are prismatic. Prismatic
joint imparts linear motion to the end effector. End effector performs the said application. The
application we have added in this motion provider is milling. We aim at creating designs on PCB
sheet heavily used in industries preparing electronic components. This machine will give designs
as output of machine with 3-D motion as basic element.

1.4 Pictorial System Overview:

Fig: 1.1 Pictorial Diagram

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1.5 Main Features:
1.5.1 Work Space:
As explained earlier, this machine is using Cartesian coordinate system which can produce linear
3-axis motion. 3 stepper motors play the role of 3 axis. These motors are used to produce a three
axis motion. This motion is linear which leads to the required point of position.

Fig: 1.2 PPP Configuration [8]

1.5.2 Lead Screw Mechanism:

it consists of a threaded rod that translates rotational motion into linear motion. In this mechanism,
lead screws generate sliding rather than rolling friction between nut and screw.

Fig: 1.3 Lead Screws [9]

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1.5.3 Milling:
Milling is the application of this project. Milling in this project is performed through drill. The drill
with the help of a chuck is connected to the z-axis on which there is a DC motor. And in other
words, this can be considered as the 4th axis of the machine which creates a rotatory motion.

Fig: 1.4 Milling [10]

1.6 Milling Benefits:

Can be utilized in a huge style of design environments.

• For engraving doors making designs on the surface.

• Making casts of statuary
• Producing designs on coins.

1.7 Report Outline:

The rest of this dissertation is organized as follows: In Chapter 2, we will give a brief background
and Domains related to Robotic world, chapter 3 will review literature of this dissertation study.
Chapter 4 will give methodology
.

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1.8 Background:
The brief research and study of previously elaborated experiments and results have a broad role in
concluding and finalizing our effort.

1.9 Robot Domain:

A consequently worked machine that replaces human exertion was hard to envision; in the
perspective of appearance or perform capacities in a human like way. By augmentation,
mechanical building manages the outline, development, and operation of robots. A robot is a
mechanical or virtual manufactured operator, which has its very own mind. By and by, it is
generally an electro-mechanical framework, which by its appearance or developments passes on a
feeling that it has aim or organization of its own. In 2015 the number of industrial robots sold
worldwide surpassed the 240,000unit mark for the first time. This corresponds to global year-on-
year growth of 8 percent. The greatest demand was again registered by the automotive industry.
China’s highest demand of industrial robots increase by 16 %, Europe rose by a record of 9 percent
to nearly 50,000 units and Canada and Mexico a total of 34,000 units by growth of 11%.

Fig: 1.5 Different Types of Robot [16]

xvi
1.10 Milling Domain:
There are numerous zones where robots can be substituted for human; amongst them, Milling is one
of the most used zone. In the early stages of life with the sense growing eras, people used hand
handled tools to create designs on doors, PCB windows and made statues etc. That was a time when
technology was not so common. Now the developed sense has produced robots to perform the
required tasks and made life easy. The ergonomic purposes are well played by 3-D robots from
which 3-D linear robot is most famous which we are calling the Milling machine. This application
of robots has become the fundamental need of every personal to meet their standards of life. Other
than Milling, Cartesian has found its many other applications like weight pulling, picking an object
and placing it to the desired position, making casts etc.

Fig: 1.6 Engraver

CHAPTER 2
xvii
 Literature Review

2.1 Etching:
Is a scheme of creating prints from a metal plate, usually copper into which the project design
has been scratched by acid. The copper plate at first covered with an acidic material, called the
etching ground, through that ground required design is printed on the board. This, normally, is
made up of candle wax, blacktop or that kind materials. The plate is then exposed to HNO3,
which removes those areas of the plate isolated by the ground, creating a pattern of dipped lines.

These lines grip the ink and when the plate is exposed to moist paper, the design allocates to the
paper, making a completed print In the diversity of etching known as aquatint, a copperplate is
exposed to acid through a coating of fluid granulated resin, leaving an equally pitted surface that
produces wide areas of tone when the grains are removed and the plate is printed. Etching and
aquatint are often combined in a print by means of successive workings of its plate.

Etching is excessively used technique in industries and printing market. The practice of creating
prints from etched metal plates raised out of the traditional etching designs on armor and was
embraced by printmakers as an cool way of carving, a process of creating prints from metal
plates notched with a tool called a burin. This method of printing is quite different from traditional
techniques.[2]
Historical Background: This is the historical review of the etching process. The first dated
etching was made in 1513 by the Swiss artist Urs Graf, printed from iron plates. After him, the
creative German artist Albrecht Dürer made five etchings very first time. In his “Cannon” (1518),
he tried to copy the formal, planned quality of etchings, revealing that etching’s naturalness and
smooth line were not valued in northern Europe, since then. The Italian sculptor of sixteenth
century Parmigianino, however, made etchings with graceful, easy knocks that showed his
complete understanding of the procedure. In France, the artist Jacques Callot used engraving as an
assistance to etching in his book “Miseries of War” (1633). He not only engraved the metal when
drawing through the ground but also covered the lines with an engraver’s tool (burin) after the
plate had been wide-open to acid.

xviii
Hence, etching is a traditional process to cut unprotected metal plates for creating patterns or
designs using strong acids or mordant. It is the method of old printmakers but it is also excessively
in use at these days, too.[2,3]

2.2 Printing:

Is a process, technique for replicating text and images by means of a master form or prototype or
template, simply is a technique of producing imitations of things. The five main printing processes
are differentiated by the technique of image transfer and by the broad type of image carrier
engaged. Relying upon the process, the printed image is moved to the substrate each directly or
indirectly. In direct printing the image is directly transferred from the image carrier to the required
module, e.g. of direct printing are flexography, screen printing, gravure and printing process letter
press. In indirect printing, also called as offset printing, the file containing required data (image
or text) is first moved from the image carrier to the second medium(blanket cylinder) and then to
the substrate. Lithography, now a days, dominating technique now a days, is the best example of
indirect printing.

The process of printing can mainly be classified as one of four types:

• planographic,
• relief
• screen, or
• Intaglio.

In planographic printing, the image and non-image areas each are on the same plane. The image
and non-image areas are distinct by differing physiochemical possessions. Lithography is a
planographic process.

In relief printing, the image or printing area is raised above the no image areas. The five major
printing processes, those depending on relief printing are flexography and letterpress.

In the intaglio process, the no printing area is at a normal surface with the substrate while the
printing area, containing of tiny etched wells of differing penetration size, is settled. Gravure is an

xix
intaglio process. In the screen process, known as porous printing, the image is moved to the
substrate by forcing ink through a porous net which carries the image .

Each printing process can be divided into three major steps:

• Pre-press,
• Press and
• Post-press

Prepress technique include that series of steps during which the image is transferred to the image
carrier such as a plate, cylinder, or screen. Prepress operations include arrangement and typesetting
image carrier preparation.

Press includes the real process of printing.

Post-press mainly involves the assembly of printed materials and consists of binding and finishing
operations.[3]

2.3 CNC Machine:

CNC is abbreviated as computer numerical control machine. Numerical Control machine uses
computer commands to meet the specific task performed. CNC machines has a unique human
machine interface environment. An Numerical Control machine converts the text or shaped given
to it in the form of computer instructions into a three dimensional practical piece of art or a product
like this. Numerical Control machines aids a motorized controllable tool and often a motorized
steerable platform, which are both controlled by a computer program, in accordance with definite
input commands. Commands are delivered to an Numerical Control machine in the form of
pictorial computer-aided design files, which are converted into a successive program of machine
control commands, and then performed.

Computer Numerical Control machine has the ability to perform in various degrees of freedom and
most common is in 2D at-least. And tool goes in third dimension (Z-axis). The position of the
tool is compelled by direct-drive servo motors in order to run highly precise movements, or in
older designs, motors through a series of step-down gears.

xx
2.4 Efficient Path Planning:

Is a process in which the CNC machine decides or choose the best path for functioning. As when
a specific shape or diagram is provided to the machine, definitely, it has a number of ways
adopting, it can perform. But CNC machine should choose that path, at which it has to cover lesser
distance comparatively. Then it would be an efficient path for the performance.[3]

2.4.1 PC Based control and modeling of CNC Machine

This paper is prepared by Stephen J. Robber and Yung C. Shin at School of Mechanical
Engineering, Purdue University, 1288 Mechanical Engineering Building, West Lafayette, USA.

A PC-based open structural design computer numerical control machine (CNC) is presented to
control grinding machines. The controller is executed on two systems:

(1) a one degree-axis milling mechanism using analog control signals where the computer based
controller supposes all Computer Numerical Control functions and

(2) a three degree-axis drilling mechanism well-ordered by digital signals where the present
Computer Numerical Control continues to monitor marginal functions but the Computer based
system produces the reference instructions for spindle and axis.

System models are established by using sine and cosine inputs to form the time response and
frequency of every axis drive. An investigational controller is executed with the open structural
design controller to uphold constant ultimate cutting force in the existence of unreliable machining
situations in end grinding. An accepted cross over coupling regulator is also introduced to lessen
chasing and shape error for a two-dimensional outline via the open structural design controller.[4]

2.4.2 System & Method for positioning work-pieces on CNC machines

This paper was invented by Kennenth J. Susnjara,Santa Claus, Ind. Its assigned to Thermwood
Corpration, Dale Ind.
xxi
An association for arranging a pattern on a work-piece on the work table of a CNC in a pre-
programmed position, to perform a work-function on the work piece, containing 1 st locus points
predisposed on the work-table having a pre-determined latitudinal link to the outline in the
prearranged position, a transfer piece having 2nd reference points notable with the 1 st reference
points and locator points notable with the work-piece design, the second situation points disposed
in a prearranged three-dimensional link to the detector points, a system for detachably getting the
work-piece to the allocation piece when the allocator points are prepared in archive with the work-
piece design, and a system for unteachably securing the work-piece to the work table whenever
the work-piece design is prepared in the prearranged location.

2.4.3 Firefly algorithm for path optimization in PCB holes drilling process

This paper is published by 10 authors and some of them are M. M. Ismail, M.A. Othman, H. A.
Sulaiman. Published in: 2012 International Conference on Green and Ubiquitous Technology.

In Printing Circuit Board holes drilling process, the time occupied for a task accomplishment
heavily depend on the remoteness travels by the tool bit of the Computer Numerical Controller. In
accordance, to lessen the distance traveled by the drill tool, Firefly Algorithm may be used.

The projected prototypical relates Firefly Algorithm to pursuit for the elevated way in Printing
circuit board holes milling process. Every means' position signified a conceivable path that can be
reserved by the drill tool. The suitability of the agent is contrariwise relative to the remoteness of
the path where the shorter the remoteness, the better the suitability of an mediator. Then, the agents
compare their suitability with each other. Mediator will try to improve its suitability by moving
closer towards other mediator with better suitability. The process repeated until extreme repetition
achieved. Performance of the planned model is likened with other writings using a typical case
reading.

2.4.4 Automated PCB Drilling Machine with Efficient Path Planning

This paper is written by P.L.S.C Alwis, A.S Premarathna, Y.P. Fonseka at Department of
Mechatronics, Faculty of Engineering, South Asian Institute of Technology and Medicine
(SAITM), Sri Lanka.

xxii
In Printing Circuit Board drilling machines, the locality of the tool holes are nourished into the
apparatus and the Printing Circuit Board will be bored at the equivalent coordinates. This paper
offerings the project of a Printing Circuit Board drilling machine, where the tool holes are
mechanically spotted from image of the circuit rejecting the need to physically enter the mill hole
coordinates’ axes. Additional, the boring machine uses a path forecasting algorithm, which is
skillful of approximating an efficient navigating path for the tool diminishing the length of travel.
The path forecasting algorithm improves the use of the engines and other mechanical paths
convoluted in the process while dropping total time taken to navigate all the mill holes.[4]

2.5 Simulation tools to study behavior of CNC

This paper is written by Sorin Tarnovean, Radu E. Breaz, Cristina Biris, and Octavian C. Bologa.
In this paper the writers presents an integrated simulation approach for studying the behavior and
accuracy of CNC drilling machines in different working regimes.

Forces involved in the process (cutting forces and friction forces) are relatively smaller and the
feeds are significantly higher within the process of drilling. This research is based upon a model
of a feed drive, using a DC servomotor as actuation device. This kind of motor is widely used in
the design of CNC machines by a large number of manufacturers. The CNC feed drive acts as a
position control system, but with a numerical character.

The authors proposed a straight-forward mathematical model of a feed axis of a CNC machine,
based upon continuous transfer functions and presented a method for calculation of the model
parameters. Each diagram within the proposed set allows the user to test the dynamic behavior,
the tracking and contouring errors on each axis of the machine and to take corrective actions to
improve them by altering the control parameters of the position controller.

xxiii
 CHAPTER 3
Mechanical Design

3.1 Mechanical structure:

The Mechanical Structure of our PCB printing and drilling machine mainly comprise of following
components:

• Precisions rods
• Linear Bearings
• Lead screw
• Radial bearings
• Frame
• Drill bit

3.1.1 Precision Rods:

Precision linear rods are meant for automation use. The linear rods we are using is 12mm in
diameter and nearly 18cm in length these are highly precise, hardened and Polished stainless steel
rods promise to offer great running life and precision. Linear give the most consistent service
hardness and also depth of hardness across a various range of size and offers increased
performance. Their diameter can vary up to 0.001mm which is very good precision. Carriage
assembly can move along these rods with the help of linear bearings. Precision linear rods are
meant for automation use. Linear rods we are using is 12 mm in diameter and nearly 3 feet in
length these are highly precise hardened and a list stainless steel rods promise to offer great running
and precision carriage assembly will move along these roads with the help of linear bearings.

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 Fig: 3.1 Precision rods [11]

3.1.2 Linear bearings:

A linear bearing gives a low friction motion on a single axis. Their cost is more than classical
round ball bearings, but in carriage design they are simpler to integrate. The specification of linear
bearing we are using in or project are 12mm in diameter and 18cm in length. For precise movement
of carriage assembly with precision linear rods linear bearings are used.

Fig: 3.2 linear bearings [12]

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3.1.3 Lead Screw:

Lead screw is used as a linkage in a machine that is used to change a turning motion into linear
motion. It is also known as power screw or translation screw. Due to their large area of sliding
contact between their male and female members, screw threads have larger frictional energy losses
compared to other linkages. They are not typically used to carry high power, but more for
intermittent use in low power actuator and positioner mechanisms. Linear bearing can slide over
the Lead screw to provide a sooth motion for machine to do the job smoothly with higher efficiency
and better result.

Fig: 3.3 lead screw [9]

3.1.4 Radial Ball Bearing:

It is the type of rolling element bearing which uses balls in order to maintain separation between
the bearing races. The main objective of ball bearing is to minimize rotational friction and then
support radial and axial loads.

Ball Bearings are a type of rolling element bearing which uses balls to minimize the friction. Radial
ball bearings are friction reduction devices that carry loads radially around its axis. A subtype
of ball bearings, they operate through the use of lubricated steel balls placed between two grooved
rings. They are frequently called deep-groove bearings or Conrad bearings. While these types of

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bearings can accommodate some axial thrust, thrust bearings or roller bearings should be used for
designs with a high axial load.

Fig: 3.4 Radial ball bearing [13]

3.1.5 Frame:

The primary purpose and most important design of frame is that it must be solid. As end effector
and motors moves, the robot will shake and if the frame is wobbly then accuracy suffers.

We have developed our PCB machine base design of PVC for bottom frame and upper sliding
part. PVC is light weight then metal and it comes in an amazing number of shapes and sizes to suit
whatever style need and easy to design. It is easily available in market and easy to machine if the
part is damaged in future.

3.1.6 Drill Bits:

Drill bits are cutting tools used to remove material to create holes, almost always of circular cross-
section. Drill bits come in many sizes and shapes and can create different kinds of holes in many
different materials. In order to create holes drill bits are usually attached to a drill, which powers
them to cut through the workpiece, typically by rotation. The drill will grasp the upper end of a bit
called the shank in the chuck.

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 Fig: 3.5 Drill Bit [14]

3.2 3D Cad Model Design:

Fig: 3.6 CAD

3.3 Ca

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3.3 Calculations:

• Force calculations
• Torque calculations
• Motor selection

3.3.1 Force Calculations:

Force required to move centered carriage,

We know that

F = mg

m = 1.15 kg

g = 9.81 m/s2

F = 11.28 N

Stainless steel co-efficient of static friction,

µs = 0.8

Fs = 9.025 N

Stainless steel co-efficient of kinetic friction,

µk = 0.58

Fk = 9.025 N

Force required to move x-axis,

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F = mg

m = 3.986kg

g = 9.81 m/s2

F = 39.10 N

Stainless steel co-efficient of static friction,

µs = 0.8

Fs = 31.28 N

Stainless steel co-efficient of kinetic friction,

µk = 0.58

Fk = 22.67 N

Force required to move y-axis,

F = mg

m = 4.32kg

g = 9.81 m/s2

F = 42.37 N

Stainless steel co-efficient of static friction,

µs = 0.8

Fs = 33.90 N

Stainless steel co-efficient of kinetic friction,

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µk = 0.58

Fk = 27.570 N

Force required to move z-axis,

F = mg

m = 2.2kg

g = 9.81 m/s2

F = 21.58 N

Stainless steel co-efficient of static friction,

µs = 0.8

Fs = 17.26 N

Stainless steel co-efficient of kinetic friction,

µk = 0.58

Fk = 12.51 N

3.3.2 Torque Calculations:

Torque required for x-axis,

Tx = r * Fk

Tx = 0.91 * 22.76

Tx = 2.21 N cm

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Torque required for y-axis,

Ty = r * Fk

Ty = 0.91 * 22.76

Ty = 2.21 N cm

Torque required for z-axis,

Tz = r * Fk

Tz = 0.91 * 22.76

Tz = 2.21 N cm

3.3.3 Motor Selection:

NEMA 17 bipolar

Holding Torque = 43 N

The torque of selected motor is greater than the required torque in order to improve the
requirements that cause the machine highly precise for higher load conditions.

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 CHAPTER 4

Software and Hardware

4. Software Working:
The softwares which are implemented in this project are very versatile and they are listed below
following the short introduction and some features for their selection.

➢ CopperCAM
➢ GRBL
➢ Arduino

4.1 CopperCAM

This is an application for managing isolation engraving, drilling and cutting printed-circuit board
prototypes. It does not integrate the direct drive of a CNC milling machine, but simply outputs
files that can be loaded and used by external driver software, or data to be sent to the machine.

4.1.1 Working with CopperCAM

• Management of 4 circuit layers, plus drills, plus cut-out contours, plus

centering holes
• Real-time display of equipotential paths through layers
• Automatic calculation of isolation contours, simple or multiple
• Manual modification of isolation contours (deletion or addition with auto-
snap)
• Enforcement of isolation between very close pads
• Selection of tracks to be engraved at path centre (texts, logos or references)

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4.2 GRBL

GRBL is an unrestrained, exterior thing, exalted show software for controlling the event of
machines that run, that puddle things, or that urinate things run, and gift run on an honorable
Arduino. If the creator motion was a manufacture, GRBL would be the manufacture standardized.
Most ingenuous inspiration 3D printers individual GRBL in their whist. It has been adapted for use
in hundreds of projects including laser cutters, robot like sailor open source phenomenon [7].

Fig: 4.1 GRBL [7]

4.2.1 Working with GRBL

GRBL is a powerful tool honorably saying a perfect controller demandingly used in design
industries to convert G-Codes into machine codes. Image after coming from the G-Cam as G-Codes
moves to GRBL. GRBL converts G-codes to machine codes which are helpful for machine to
understand.

4.3 Arduino

Arduino is an opened shaper tool element and software relationship, propulsion, and psyche
conformity designs and manufactures single-board microcontrollers and microcontroller kits for
mercantilism digital devices and mutual objects that can signification and classical objects in the
physical and digital quality.

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 Fig: 4.2 Arduinos [15]

4.3.1 Working with Arduino

Arduino is used universally used as controller in machinery domains. Here in this project arduino
has been utilized to control the CNC sheet mentioned above. When the input in the form of G-codes
is fed to GRBL, it is further moved to arduino’s ATMEGA 328 that activates CNC sheet.

*/

#include <grblmain.h>

void setup(){

startGrbl();

Void Loop(){}

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Fig: 4.3 Arduino Activation of CNC sheet

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4.4 Hardware Working
The electrical components that are used in our project to achieve our goals using G-Codes by the
softwares are:

➢ Arduino
➢ CNC shield
➢ Power supplies

4.4.1 Arduino

Arduino is an open-source hardware and software company, project and user community that
designs and manufactures single-board microcontrollers and microcontroller kits for building
digital devices and interactive objects that can sense and control both physically and digitally .

Fig: 4.4 Arduino

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4.4.2 CNC Shield

This expansion board as a driver expansion board, can be used for engraving machines, 3D
printers. It has total of four slots, can drive four A4988 stepper motor. The A4988 is a complete
micro stepping motor driver with built-in translator for easy operation. It is designed to operate
bipolar stepper motors in full-, half-, quarter-, eighth-, and sixteenth-step modes, with an output
drive capacity of up to 35 V and ±2 A. The A4988 includes a fixed off-time current regulator
which has the ability to operate in slow or mixed decay modes. Each stepper motor only need two
IO ports. In other words, six IO ports can be well managed for three stepper motors. It is very
convenient to use.

Fig: 4.5 CNC Shield

Specification

• GRBL 0.9 compatible. (Open source firmware that runs on an Arduino UNO that turns G-
code commands into stepper signals)
• PWM Spindle and direction pins
• 4-Axis support (X, Y, Z , A-Can duplicate X,Y,Z or do a full 4th axis with custom firmware
using pins D12 and D13)
• 2 x End stops for each axis (6 in total)

Applications of Shield

• 3D Printer
• Engraving machine

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 CHAPTER 5

Experiments and Results

5.1 Results

5.1.1 PCB Machine:

The final structure of our PCB machine contains all the wires packed in hot sleeves. With drill bit
mounted on center carriage and rotatable x-axis rod, the assembly is retractable and portable.
Final model and actual picture of our machine is given below:

Fig: 5.1 Hardware Model Manufactured

5.1.2 Printing and Drilling Area

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This machine has a working area of 16inches by 16inches. It can print any circuit on PCB sheet of
12inches by 12inches. And this machine can engrave the circuit on PCB sheet with good accuracy
and fine finishing.

Fig: 5.2 Working Area

5.1.3 Low Price

Price is a key factor in any project. PCB Machine with such accuracy and reasonable working area
cost too much. So, we have kept our focus on minimizing price and reduced price very well.

5.2 Software Configuration:

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5.2.1 Porteous:

First of all open the Porteous and we draw the circuit diagram. Select the desired
components and made connections. Then Made PCB Layout and auto route it.it will
customize the Paths and condensed it to minimum space. Now circuit is ready. Go to
output and click on generate Gerber or Excellon files. Here we see a new window in
which we select bottom copper, top silk, drilling and sides cut out and click ok. It will
generate a TXT-File which is compatible for copper CAM.

Fig: 5.3 Circuit Diagram

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Fig: 5.4 Circuit Layout

Fig: 5.5 Generate Gerber

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 Fig: 5.6 Proteous output

5.2.2 Copper CAM:

Open the Copper CAM software and go to file the open the new circuit and then Drills
that is txt-files generated by Proteous. Once the circuit is open in copper CAM then
we can change each and every thing according to our desired specification. Now
circuit is opened in copper CAM.

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 Fig: 5.7 Circuit

• Go to file open Off-set and set it at zero. Open Origin, you have choice to set
it at zero or you can manually mark the point of origin on the circuit opened.

Fig: 5.8 off-set and origin

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 • Go to Parameters open toll library and set the end effector angle at zero.

Fig: 5.9 Tool Library

• Again go to parameters and open selected tools. This is the major part of our
software in which Depths, Margins and Speeds of Engraving, Drilling and
Cutting out are set at the same plate form.

Engraving tool

Depth 0.25 mm/s

Margin 0

Speeds 5mm/s

Cutting tool

Depth 2 mm/s

Margin 0

Speeds 5mm/s

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Drilling tool

Depth 2 mm/s

Margin 0

Speeds 5mm/s

Fig: 5.10 Active Tool

• Now its time to shape the opened circuit as PCB board. Click on the calculate
contours and sat it at 1 which is the No. of rounds on a single layer.

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Fig: 5.11 Active Contours

Fig: 5.12 PCB Circuit

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• Now Click on the Drill List and identify the all Drill holes.

Fig: 5.13 Drilling Tools

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• Now last but not least click on the Mill , new window will opened and click on the
Engraving and Drilling to generate a g code.

Fig: 5.14 Engraving output Generator

Fig: 5.15 drilling output generator

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5.3 GRBL:

GRBL is an unrestrained, exterior thing, exalted show software for controlling the
event of machines that run, that puddle things, or that urinate things run, and gift run
on an honorable Arduino.

GRBL software is an user interface which has manual interface as well as user control.
To calibrate the platform click on the Axis control to manually control the x-axis, y-
axis and z-axis.

We can change the step size from 0.1 to 1000 times.

So upload the g-code generated by copper cam i.e. circuit can be uploaded into GRBL
using choose file. Once if the circuit is loaded its setting can be seen in object
placement tab.

Fig: 5.16 GBRL Interface

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Fig: 5.17 GRBL Interface with Circuit

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5.4 Machine Quality:

Fig: 5.18 output 1

Fig: 5.19output 2

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 CHAPTER 6

Conclusion and Future Recommendations

6.1 Conclusion

CNC technology can revolutionize and re-shape the machining world. Advancements
in CNC technology can significantly alter and enhance the way of manufacturing
products and production of goods worldwide. The importance of any invention can
be judged by determining which of human needs it can fulfill. Engraver CNC machine
can have an application in almost all of the categories of machining and cutting. One
of the main advantages of this concept is that, parts of any material could be engraved.
This concept can enable fast, reliable, and repeatability of working means of
producing products which can still be machined cost effectively due to automation of
processes and distribution of machining.

6.2 Future Recommendations

Everything is never 100% efficient. There is always a hole which can be filled up by the food of
knowledge and its implementation. There are many considerations which can be the key objective
of researchers to improve the performance of this engraver. Some of the many important
perceptions are typed below.
➢ Size: Size of the machine can be increased to have a large work area because of which large
work pieces can be engraved in a single move.
➢ Speed: Using heavy motors embedded with heavy power supply can be the best options to
increase the rate of engraving and to save the time a demand imposed on modernity.
➢ Software: High performance software have a solid grip on the product. Aspire has been the
charming option of industrialists in engraving domains but it is difficult to use specially for

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 new comers. In future, it can be made happen that a person just feed a picture to the machine
and machine do everything for you.
➢ Internet control: For making the machine more intelligent, GPS can be utilized. The
worker just connect himself even from the far away side of the area and then feed the input.
The machine should do things for him.
➢ Surface finish: The casing and overall structure of the robot can be made more finished.
➢ Strength: The casing and overall structure of the robot can be made stronger.
➢ Endurance: The improvements in the mechanical structure can be made to bear more
stress, strain and other forces applied on the robot.

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References:

[1] Esther T. Ososanya (Tennessee Technological University, Dept. of Electrical Engineering,

Cookeville, Tennessee- 38505) & John Saint Joseph, Michigan Technological University,
Dept. of Electrical Engineering, Houghton, Michigan – 49931 Publication: Trans. of SICE,
Vol. 35, No. 1, PP. 122129, Jan. 199

[2] Rodrigo Basniak, “Design of a pcb milling machine”, ABCM Symposium Series in
Mechatronics-Vol 5, pg 1339,2012.

[3] Literature Review on Variable Frequency Drive, Dhaval A. Shah Pravin G. Sanas Amol O.
Mahajan Mahadev A. Jamdade Mayuresh B.Gulame,Department of Electronics &
Telecommunication Engineering, IJSRD - International Journal for Scientific Research &
Development| Vol. 3, Issue 08, 2015

[4] Rodrigo Basniak, “Design of a pcb milling machine”, ABCM Symposium Series in
Mechatronics Vol 5, pg 1339,2012.

[5] Zulkifli Tahir, Nur Azman Abu, Shahrin Sahib, Nanna Suryana Herman, “CNC pcb drilling
machine using novel natural approach to euclidean tsp” , Universiti Teknikal Malaysia, IEEE
2010

[6] Yuan, S., Peng, Q., Palczewski, K., Vogel, H., and Filipek, S. (2016b). Angew. Chem. Int. Ed.
Engl. 55, 8661–8665

[7] https://github.com/grbl/grbl

[8] www.3dhubs.com/knowledge-base/how-design-parts-cnc-machining

[9] https://spool3d.ca/lead-screw-8mm-2mm-pitch-2mm-lead/

[10] https://carbide3d.com/projects/021-pcb/

[11] https://us.misumi-ec.com/vona2/detail/110300229270/

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[12] https://www.aliexpress.com/item/

[13] https://www.indiamart.com/proddetail/radial-ball-bearings-4136679333.html

[14] https://www.ffx.co.uk/tools/product/

[15] https://www.elprocus.com/different-types-of-arduino-boards/

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