The Design Of A Cnc Mill For Product Prototyping

The Design Of A Cnc Mill For Product Prototyping

Abstract

Rapid prototyping is extensively used to reduce time to vend in product design and development. moment’s systems are used by masterminds to more understand and communicate their product designs as well as to make rapid-fire tooling to manufacture those products. Computer Numerically Controlled( CNC) milling machines are part of this technology. This design will present the design of a small CNC machine, and product, and analysis of a small CNC machine. This machine has the characteristics demanded by the artificial and academic contrivers. Studying the

being machines backed in setting specifications for the new design. Comparing the performance of the new machine with being machines will ameliorate unborn designs.

Table of Contents

1 Chapter 1- preface & Problem result 1

result Methodology 2

2 Chapter 2- Performance Metrics of Numerically Controlled Machines 4

12.1 Geometrical crimes 4

Counterreaction 9

Scaling Mismatch 10

Parvis Error 12

Cyclic Error 13

Side Play 15

Reversal Harpoons 16

12.1.7 Stick Slip 18

Vibration 19

Master- Slave Changeover 20

Straightness 22

ASME Standard Test Method 23

3 Chapter 3- Performance Evaluation of Being Machine 25

Discussion o f measures of Microkinetics Performance 26

Discussion o f measures of Prolight Performance 31

4 Chapter 4- Design Specifications for the New Machine 36

5 Chapter 5- Design of the New Machine 39

The Hardware 40

The Structure 40

X & Y Axis 41

Axis Motor 43

Axis Actuator Hardware 45

Rolling Contact Bearing 48

Motor Mounting 54

Linear Slides 56

Z Axis 61

The Software

motorist and Electronics

6 Chapter 6- dimension of Performance of the New Mill

7 Chapter 7- Discussion of Results

8 Chapter 8- Recommendation for unborn Work

supplements

G & M Canons

computation distance for the Ball Screw

ImportantPartsofEMC.INI train

Diagram ofThe Driver†™ s Circuit

computation and Selection o f the Stepper Motor

Engineering delineations of GVSU Mill

References

Table of numbers

Figure2.1.1 the tackle needed for the Renishaw ballbar test. 5

Figure2.1.2 feed in, out, angular overshoot bends and the data prisoner bends. 6

Figure2.1.3 the data prisoner range of the ballhar transducer is roughly 2 mm. 7

Figure2.1.4 a plot o f timevs. transducer trip shows the period of machine

acceleration and how it would affect the integrity o f the data collected. 7

Figure2.1.1.1 an illustration of positive counterreaction. 9

Figure2.1.1.2 the interpolation of the inward step in the ball bar plot. 10

Figure2.1.2.1 an illustration of a scaling mismatch error. 11

Figure2.1.3.1 positive and negative parvis . 13

Figure2.1.4.1 an illustration of cyclic error. 14

Figure2.1.5.1 an illustration of a side play in the y axis. 15

Figure2.1.6.1 an illustration plot of a reversal harpoons error. 16

Figure2.1.6.2 an illustration o f the effect of a reversal harpoons error on the factual circle mulled on the part. 17

Figure2.1.7.1 stick- slip error as shown on a individual problem. 18

Figure2.1.7.2 the effect of stick- slip on the crafted part. 19

Figure2.1.8.1 a typical plot showing vibration error. 20

Figure2.1.9.1 a master- slave transfiguration error as captured by the ball bar individual plot. 21

Figure2.1.9.2 master slave transfiguration every 45″. 21

Figure2.1.10.1 three distinct deformations in the plot caused by an error in the y axis straightness. 22

Figure3.1.1 a plot of the ballbar test on the Microkinetics CNC express. 27

Figure3.1.2 representation of the angular error and how it can beget a scaling mismatch error. 29

Figure3.2.0 individual plot of the proLIGHT on the same scale as the Microkinetics. 32

Figure3.2.1 a plot of the ballbar test on the proLIGHT CNC machining center. 32

Figure3.2.2 duplex arrangement angular contact comportments. 34

Figure 5 a solid model of GVSU shop. 39

Figure5.1.1.1 the structure of GVSU shop. 40

Figure5.1.2.1 the X, y axis including the direct slides. 41

Figure5.1.2.1 the axis drive system. 42

Figure5.1.2.2.1 lead screw and nut. 45

Figure5.1.2.2.2 ball screw and nut. 46

Figure5.1.2.3.1 deep groove ball bearing. 48

Figure5.1.2.3.2 the motorist and the follower pulley compasses and distance. 51

Figure5.1.2.4.1 timing belt, and timing pulleys. 54

Figure5.1.2.5.1 illustration of the dovetail slides. 56

Figure5.1.2.5.2 illustration of the direct ball bearing slides. 57

Figure5.1.2.5.3 illustration of the crossed comber bearing slides. 58

Figure5.1.2.5.4 the guided direct sliding system. 59

Figure5.1.3.1 the spindle assembly. 61

Figure5.3.1 the drive rack and the G201A outside. 66

Figure6.1 the first individual plot of the new machine using a 50 mm ballbar. 69

Figure6.2- 1 individual plot of the alternate test on a 100 pm plot scale as the first test.72

Figure6.2- 2 individual plot of the alternate test on a 50 pm plot scale. 72

Figure6.3 individual plot of the final test. 74

Figure7.1 percent divagation from the compromised performance values. 79

Figure8.1 tone aligning direct bearing may beget unwanted movement of the axis 82

List of Symbols and bowdlerizations

CNC Computer Numerical Control

mm millimeter

m cadence

pm micro cadence

9 theta, the value quoted for parvis by the individual software

Dy the wavelength of the cyclic sinusoidal error

ASME American Society of Mechanical Engineers

CW Clockwise

CCWCounter-Clockwise

ISO International Organization for Standardization

JIS Japanese Industrial Standard

. ounce per inch

RPM Revolution Per nanosecond

VAC Volts of Alternating Current

Ibf pounds of force

lb pounds of weight

Deg. degree

CMM Coordinate Measuring Machine

DC Direct Current

Fa axial force

L lead of a ball screw( elevation)

T necklace

e effectiveness

n pi( p belt inclination angle

C distance between centers of pulleys

Ri compass of the motor pulley

Ri compass of the screw pulley rad radians

F B m a x the maximum radial force

a angle of underpinning of lower pulleycoefficient of disunion between pulley

HP Horse Power

AFBMA Anti Friction Bearing Manufacturers Association

P original cargo

Fr applied constant radial cargo

V gyration factor

X radial factor

Y thrust factor

L fatigue life expressed in millions of revolutions

C the introductory dynamic cargo standing

NC Numerical Control

CAD Computer backed Design

CAM Computer backed Manufacturing

DOS Disk Operating System

PCI supplemental element Interconnect

EMC Enhanced Machine Controller

API operation Programming Interface

NIST National Institute of norms and Technology

GUI Graphical stoner Interface

MDI Machine Device Interface

PC particular Computer

TIL Transistor- Transistor sense

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