Design and Fabrication of 3-Axes Mini CNC Milling Machine

Abstract

The main aims of the current work are to explore the theoretical and technical procedures for design, fabricate, assembly, and testing of the electromechanical subsystems for developing a high precision cost-effective mini three-axis vertical CNC milling machine with an easy interface, high speed, less power consumption, safety and durable for rapid prototyping machining, small parts and engraving small features in the electrical and medical industry. The new Mach3mill G-Code CAD/CAM software package runs on a PC and turns it into a very powerful and economical machine controller. The 3Axis CNC driver board type Kit TB6560 was used as a micro-stepping drive for the smooth drive of the selected stepper motors. The fabricated prototype CNC milling machine with an easy interface that can interpret standard G-M codes. The fabricated machine router was tested and calibrated to determine its accuracy in different position modes for surface flatness, axes perpendicularity, and several geometric accuracies such as positioning, straightness under specific tool paths, and feed rate. The results misalignment lay around +0,01 and -0,01 mm. This means that the fabricated prototype machine movements contain 0.13° tilting on X-axis and 0.22° tilting on Y-axis. After comparison and making the required improvements in both electrical and mechanical design, the machine is in a position to milling a complex contour on soft metals with considerable accuracy and speed.