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Fabrication of Wood Carving CNC Machine

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 Fabrication of Wood Carving CNC Machine

Mr. N.Manikandan K.Sivaraam,P.Srinivasan,S.Jaiy Kishan,G.Hemnath

Assistant Professor B.tech Students
Department of Mechanical engineering Department of Mechanical Engg.
SRM University Ramapuram SRM University Ramapuram
Chennai, Tamil Nadu, India. Chennai, Tamil Nadu, India.
manisrm2011@gmail.com sivaraam224@gmail.com

Abstract—Computer Numerical control is

the automation of machine tools that are operated by precisely
programmed commands encoded on a storage medium of a
computer. CNC machine often is not economical for small
workshops and laboratory and they occupy a lot of space. In this
project the expense of a CNC machine is reduced by custom
made design, we designed it in such a way to maximize cost
effectiveness. The main objective of the project is make it user
friendly and to make it in such a way so normal user can use it
with ease. The project deals with design of Wood Carving CNC
machine using CAD software and fabricate it so as to reduce the
cost of production. CNC machine is most commonly used for
machining operation for precision work.
Keywords—Electronics, CNC, Software, Stepper Motor,
Economical.
Coresponding Author : manisrm2011@gmail.com

I. INTRODUCTION
In 1950s, American people manufactured the first CNC
machine tool of the world, and for the first time took the
development of CNC machine tool into a digitalized height,
after which all countries follow it and the CNC machine tool
industry developed prosperously for nearly 60 years until now.
Concerning of the appearance of CNC machine tool, people in
the past considered CNC machine tool as a pure “tool” and a
kind of heavy machining equipment which could be expressed
as four words: “stupid, big, dull and thick”. Along with the
increasing development and integration of science technology
and artistic aesthetics, CNC machine tool's appearance design
began to focus more on aesthetics, art and man-machine
relationship, which added more conciseness, easiness,
gorgeousness, colors and humanity into the appearance design
of large machines However, designers’ intention, preference
and needs in designing the appearance of CNC machine tools
belong to people’s subjective feeling, which is hard to grasp
and evaluate precisely [1]. Fabrication is a process of
designing a CNC machine to meet our own requirements and
specification. Our main objective was to fabricate a CNC
machine cheap and portable enough for small wood
workshops and laboratory while keeping the full functionality
of a professionally used CNC machine.
Fig 1.1 CNC Flow Chart
II. PROBLEM IDENTIFICATION
A. Existing System
CNC Machine used in existing model is too expenses for
small scale work places which requires the precision but cannot
afford the price that comes with it.
B. Disadvantages of Existing System
The cost of CNC machine makes it not economical
for small workshops and laboratory to use. The Space and
power used by the CNC machine is too for small spaced
workshops. The CNC machines requires highly skilled
workers to program the required machining component and
generate it G-Codes, which makes it very hard for workshops
as it cost more for skilled workers. The maintenance and
repair of CNC cost too high for small scale industries. The
noise caused makes it not usable in residential areas
III. LITERATURE SURVEY
Production of form surfaces increases the demands on
productivity and machining precision. Therefore, there is the
need to implement CAM production systems. CAM systems
offer a number of universal and specialized machining
strategies. Development of CAM systems is leading to
optimize the tool path for machining complex surfaces of any
shape. Contribution indicates the possibility of using CAM
system machining strategies and their comparisons with the
real machining of the chosen products. The formed surfaces,
which consists parts production from, can be regarded from
different aspects. In the production of formed surfaces,
cylindrical / end ball milling cuts are mainly used. These
cutting tools are marked as monolithic milling cutter or as
tools with index able insert. Work possibilities of milling
machine – tool, which have used for production of specific
part, must be know. Machining conditions, which the
manufacturer's recommendations must be used for
programming the milling machine – tool. Therefore, for
programming in CAM systems are used operations, which
have to achieve the required machining quality, as well as the
reduction of machining time. The production of Maltese
mechanism was realized to compare of milling strategies as
shown in Figure 4. This consists of the drive wheel, Maltese
cross and body. The production of part was performed by 3 –
axis CNC milling Emco concept Mill 155 with control system
Heidenhain TNC 426. As stock was used dural round rod with
dimensions of Ø50 x 10 mm, Ø40 x 10 mm and aluminum
body with dimensions 65 x 75 x 10 mm Software SolidCAM
with postprocessor for mentioned control system was used for
design of NC programs. The main emphasis was made on the
quality of surface and machining time, which were achieved
by selecting the appropriate milling strategy. Roughing and
finishing strategies were selected as the appropriate strategies

IV METHODOLOGY
The methodology adopted for the design and fabrication of
the dishwasher initially started by deciding upon the washing
cycle and then proceeding to the design of the dishwasher. The
process planning, design, Procurement, Fabrication, assembly,
Cost estimation, and Software interface was done as explained
below

A. Process Planning Fig 4.1 Process Planning

Planning processes can lead to higher productivity,

higher accuracy, and faster turnaround for essential
business tasks. This lesson will dig into process planning:
what it is, why we should do it, and the steps to follow to
plan or improve a process. As shown in fig 4.1
B. Cost estimation
A cost estimate is the approximation of the cost of a
program, project, or operation. The cost estimate is the
product of the cost estimating process. The cost estimate
has a single total value and may have identifiable
component values. A problem with a cost overrun can be
avoided with a credible, reliable, and accurate cost
estimate. An estimator is the professional who prepares
cost estimates. There are different types of estimators,
whose title may be preceded by a modifier, such
as building estimator, or electrical estimator, or chief
estimator. Other professional titles may also prepare
estimates or contribute to estimates, such as quantity
surveyors, cost engineers, etc. as Shown in table 4.1
 components details quantit price
y
base plate MS 3mm plate 1 sq. 1850
Metal block Ms.blk/inner dia 10 2000
10mm
bush Metal bush 4 200
Spindle motor 300rpm 1 800
shaft coupler 0.25'' to 0.25'' 3 300
screw rod pitch 1.2 mm 3 1100 Fig 4.2 Design
stepper motor DC 12 volt 2-phase 3 3000
breakout board 5 AXIS/V5 1 1300 D. Procurement
switching 400w 36v/11A 1 2250
The act of obtaining or buying goods and services.
power supply The process includes preparation and processing of a
parallel cable DB25 1 200 demand as well as the end receipt and approval of
Shaft rod Chrome steel 2 m 2 1200 payment. The process of procurement is often part of
usb cable Converter 1 100 a company's strategy because the ability to purchase
procurement total 17640 certain materials will determine if operations will continue.
Fabrication 6000 A business will not be able to survive if it's price of
Total 23640 procurement is more than the profit it makes
on selling the actual product. As shown in Table 4.2
Table 4.1 Cost Estimation S No Materials
1. Base Plate 1x1m
C. Design 2. Metal Block and Screw Rod 1m
Design is the creation of a plan or convention for the 3. Stepper Motor-3 of 1N/m
construction of an object or a system (as in architectural 4. Spindle Motor- 1 of 800rpm
blueprints, engineering drawings, business processes, circuit 5. Breakout Board for mach3
diagrams and sewing patterns). Design has different 6. Software-mach3
connotations in different fields. In some cases the direct 7. Limit switches- 6pieces
construction of an object (as in Table 4.2 Material
pottery, engineering, management, cowboy coding and graphic Base plate is the plate on the entire structure of the CNC rest.
design) is also considered to be design. Another definition for It Provides rigidity and Support the CNC machine. It must be
design is a roadmap or a strategic approach for someone to selected as per the requirement dimension. As shown in fig 4.3
achieve a unique expectation. It defines the specifications,
plans, parameters, costs, activities, processes and how and what
to do within legal, political, social, environmental, safety and
economic constraints in achieving that objective. As Shown in
figure 4.2

Fig 4.3 Base Plate

The Metal block and Screw rod are used. A threaded rod, also
known as a stud, is a relatively long rod that is threaded on
both ends; the thread may extend along the complete length of
the rod. They are designed to be used in tension. As shown in
Fig 4.4
Fig 4.4 Screw rod
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 then 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. Our motor is Nema 23 with 1N/m torque and bi-polar
motor.
Fig 4.5 Stepper motor
Spindle Motor is a small, high-precision, high-reliability
electric motor that is used to rotate the shaft, or spindle, on
which the platters are mounted in a hard disk drive (HDD).
Spindle Motor used is 800rpm with high torque with in build
attached chuck. Refer Fig 4.6
Fig 4.6 Spindle Motor
Breakout board with mach3 support. This Breakout board is
designed to separate all connections of the Builder Brain so
individual components and BYOB boards can be directly
connected. While the Breakout board is designed for easy
connection with the BYOB series of boards (Push, Turn
Slide), it can also be used to connect and manage standalone
components and third-party circuit boards. The Breakout
board has three main sections: button connections, [LED
connections], and analog connections (for inputs such as
knobs and sliders).Please Refer Fig 4.7
 Fig 4.7 CNC mach3 Breakout Board

E. Fabrication
Manufacturing process in which an item is made
(fabricated) from raw or semi-finished materials instead of
being assembled from ready-made components or parts.
Metal fabrication is the building of metal structures by
cutting, bending, and assembling processes. It is a value
added process that involves the construction of machines
and structures from various raw materials. A fab shop will
bid on a job, usually based on the engineering drawings,
and if awarded the contract will build the product. Large
fab shops will employ a multitude of value added processes
in one plant or facility including welding, cutting, forming
and machining.
Fig 4.9 Assembly Photo
The metal blocks are first milled according to required sizes
and drilling is done as per the required design of the project
for harnessing and screw rod passage. As shown in Fig 4.8 G. Software Interface

In computing, an interface is a shared boundary

across which two separate components of a computer
system exchange information. The exchange can be
between software,computerhardware, peripheral devices, h
umans and combinations of these. Some computer
hardware devices such as a touchscreen can both send and
receive data through the interface, while others such as a
mouse, microphone or joystick are one way only. We
utilized the mach 3 software for interface. Please refer Fig
4.10

Fig4.8Milling Process

F. Assembly
An assembly line is a manufacturing process (most of the
time called a progressive assembly) in which parts (usually
interchangeable parts) are added as the semi-finished assembly
moves from workstation to workstation where the parts are
added in sequence until the final assembly is produced. By
mechanically moving the parts to the assembly work and
moving the semi-finished assembly from work station to work
station, a finished product can be assembled faster and with
less labor than by having workers carry parts to a stationary
piece for assembly. As seen in Fig 4.9

Fig 4.10 Software mach3


V COMPLETE IMAGE OF THE CNC MACHINE
The complete image of our CNC machine with fully integrated
view of the board and computer using the mach3 software. As
shown in Fig 5.1
Fig 5.1 Finished Photo of CNC
VI PROBLEM SOLUTION
A. Economical Design
We have designed the project in such a way that so
has to reduce the cost and be cheaper and available for small
scale industries
B. Space Occupied
The Design is in such a way as to reduce the space
used with compromising the efficiency of the CNC machine.
C. The user friendly interface
This we achieved through the use of mach3 software
from airsoft. The main advantage is that we can directly
convert .jpg and .bmp to G-Codes which can be easily
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understood by the Computer and be processed. The g-codes
are converted to the impulses using the breakout board.
VI CONCLUSION
There is a huge difference in the way the old and the new
wood carving machine works and even looks. The new
machine even looks much more organized and compact. There
is a tremendous improvement in the way the new machine
operates over the old conventional lathe. The new machine is
much more accurate and fast as compared to the old one which
is evident while Job Trials and Commissioning. The Space
occupied in much less compared to the existing model We get
the whole feel of a new CNC machine at about 1/3rd Price
without compensating on accuracy and efficiency.
REFERENCES
[1] Appearance Design Evaluation on CNC Machine Tools Based on Fuzzy
Synthetic Evaluation Model, college of mechanical and electrical
engineering, agricultural university of HeBei,071000, china
[2] Design and Structural Analysis of CNC Vertical Milling machine bed,
Department of Mechancial engineering, SIR C.R.R College of
Engineering E-ISSN 0976-3945.
[3] Fabrication of Low Cost 3-Axis Cnc Department of Mechanical
Engineering SriKalahateeswara Institute of Technology,
Srikalahasti,A.P, India ISSN (Online): 2319 – 6734, ISSN (Print): 2319
– 6726
[4] A literature review on machining of different materials with CNC Jain3
1M.Tech. Student, Punjab, Technical University, India 2Asstt. Prof.,
PCET, Lalru, India 3 Prof. & Head of Department, Ambalacollege of
Engg., Devsthali, Ind ISSN: 2278-9359
[5] Design of a 5-Axis Fixture System Submitted in Partial Fulfillment of
the Requirements of the Major Qualifying Project Program Worcester
Polytechnic Institute Worcester, Massachusetts
[6] GENERATION FOR HIGH EFFICIENCY CNC MACHINING
APPLICATION Submitted to Department of Manufacturing
Engineering and Engineering Management September 2008