DEVELOPMENT OF A3-AXIS CNC MILLING MACHINE WITH AN OPEN SOURCE CONTROLLER

Abstract

This report presents one of the application performed by Arduino Uno when sandwiched with Grbl shield which is a high performance open source CNC controller written in optimized C-language. Here in this paper a file with extension .jpeg or .png, or .pdf is imported in an open source Aspire software which converts it into .txt or .prt file. Vectors of the imported file is traced accordingly, followed by modelling and manufacturing procedures. Once the simulation of the manufacturing file is visualized in Aspire software then G-code file is generated using post processing operation, this G-code file is saved with .txt extension. The G-code file is then browsed in Universal G-code sender software coupled to Grbl shield v0.9j and Arduino board through a laptop serial port, G-code visualizer option is available on Universal G-code sender software to visualize the manufacturing steps along with the simulation. In this way proprietory control of a controller is eliminated, and CNC machine is made user friendly.1. BACKGROUND Flexible and specialized manufacturing industry needs the use of automated robotic systems and CNC machines.(Rane et al. 2017) [19]. There has been an emergence of the condition to select the efficient and obsolete the degraded. Instantly changing dynamic lifestyle with technology embedded gadgets which has short life span are popularly accepted nowadays. As a result, if computer integrated manufacturing (CIM) and flexible manufacturing systems (FMS) forms a structure then, computer aided design (CAD), computer aided manufacturing (CAM), robots and CNC technologies acts as their main organs. Rane et al. (2016) have presented FMS for throughput enhancement [18]. Alphanumeric data is coded in a program which is prepared to control motions and functions of a CNC machine.Rane et al. (2005) have successfully eliminated these codes [17]. The motion of the tool and workpiece, turning the spindle and coolant on/off, maintaining the feed rate for machining, controlling the depth of cut, etc. are controlled by CNC machine. Allowing flexibility and accuracy in manufacturing with reduction in production time, using simple fixturing and contour machining along with successful lean implementation are some of the benefits of CNC machine.(Rane et al. 2016, 2015) [15], [16]. Along with the advantages there are a few drawbacks as well, which includes high initial cost and maintenance cost, necessity of a skilled programmer. There are wide applications of CNC machines like CNC sheet metal press, CNC lathe, CNC laser cut, CNC tube bend, CNC mill, CNC grinding machine etc. Automatic turning center, as well as machining center are also developed using CNC equipped with automation. Also along with this, CNC is also used in assembly lines, measuring the coordinates , and precise welding processes.Rane et al. (2016, 2017) [18,21] has demonstrated the applications of CNC for improving the performance of manufacturing plant. In this paper, a 3-axis CNC mill prototype is developed for user friendly experiments with open controller. Arduino equipped microcontroller is connected with the CNC shield which has drivers mounted on it to initiate the actuators, here nema-17 stepper motors are used as actuators, and for execution of participatory codes and miscellaneous codes an open source software is utilized.The controller will then convert these codes into step pulses, which will be sent as an input to actuators (stepper motors) of CNC machine. These actuators will then convert the incoming signals into rotary motions. Rane et al. (2016) [22] have improved the performance of line using CNC. Nowadays more and more machines are being converted in CNC machines due to their high accuracy, high precision, less setting time and greater repeatability. One aspect of using CNC is that unskilled or semiskilled labours can also use it effectively. According to Rane et al. (2017) [23] CNC can be used for batch as well as mass production. The basic controlling of a CNC is same as that of a printer. As CNC machines are bigger in size they are mostly used in workshops. Sarda et al. (2015) [24] have proposed use of CNC in assembly line.