Converting Conventional Lathe Into Semi-Automatic Lathe Machine
Converting Conventional Lathe Into Semi-Automatic Lathe Machine
Converting Conventional Lathe Into Semi-Automatic Lathe Machine
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1
DECLARATION
We certify that this project, which now has been submitted for accredited
assessment on the programme of study course leading to the award of Higher
National Diploma “HND” of in (Electrical and Electronic & Mechanical
Engineering) and this project is entirely our own work, that we have exercised
reasonable care to ensure that the work is original, and does not breach any law of
copyright, and has not been taken from the work of others save and to the extent
that such work has been cited and acknowledged within the text of our work.
Signature:
Adham Nader Kamal
Supervisors:
2
ABSTRACT
In competitive business world, reducing operational cost and increasing
productivity become paramount and so the development of modern technologies in
computer software, hardware, and firmware as well as the integration of these
technologies in the industrial lines has provide better and more efficient
productions can be machined. In this project, an attempt has been made to equip
the conventional lathe machine with Semi-Automatic lathe machine in order to get
more accurate dimensions and precise shape of high end products and this has been
done by exploiting all the studying subjects we have learned related to
“Electrical/Electronic and Mechanical and Software/Programming fields”. The
retrofitting process of the conventional lathe machines into semi-automatic control
lathe machine, demands two key elements, namely, mechanical and electronics
parts. In the mechanical parts, a design is made by Soildworks software to send the
G-Code to the Artcam software with the help of Mach3 software to feed the
stepper motors to the lead screw. On the other hand, in the electronics parts, an
electrical box that have electronic circuits designed by Altium Designer software in
order to test the circuits on the motors and that containing the motor driver circuit
that designed in order to control the motor movement and GRBL software board to
control the direction and speed of the steeper motor. The assessment and
evaluation will be done after testing and start the turning operation and that
succeeded in reaching our main target of the project.
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Table of Contents
Acknowledgement .................................................................................................................................... 1
DECLARATION ..................................................................................................................................... 2
ABSTRACT ............................................................................................................................................. 3
1.5.1 Automatic Mini CNC Machine for PCB Drawing Technology ............................................. 15
4
1.5.5 The Importance of CNC Manufacturing Education to The Economy ................................. 18
5
4.2 First Evaluation Stage ..................................................................................................................... 58
4.8 References......................................................................................................................................... 89
4.7.3 Appendix C: X Axis Motor Driver Specifications and Features Model TB6600 ...................... 97
4.7.5 Appendix E: Spindle Motor Driver ABB Type Model ASC355 ............................................... 99
6
List of tables
Table 1.1 Comparison between Altium Designer and Proetus Design Suite ..........22
Table 1.2: Advantages and disadvantages of Auto CAD program..........................26
Table 1.3 Soildworks advantages and disadvantages ..............................................27
Table 1.4 Comparison between GRBLGRU and Universal G-Code Sender ..........28
Table 1.5 The project budget list .............................................................................29
Table 4.1 The Total Power Consumption Of The Electrical Parts ..........................60
Table 4.2 Specifications of MACH3 Interface Breakout Board .............................62
Table 4.3 The measurement of the applying samples ..............................................85
Table 4.4 The measurement of the applying samples ..............................................86
7
List of figures
Figure 1.1 Schematic Circuit using Altium Designer 2017 .....................................23
Figure 1.2 Printed Circuit Board Circuit Using Altium Designer 2017 ..................24
Figure 1.3 Schematic Circuit using Proteus Design Suite 8 ....................................25
Figure 1.4 Printed Circuit board using Proteus Design Suite 8 ...............................25
Figure 1.5 Gantt chart Source: Researcher .............................................................31
8
Figure 4.1 The final form of PCB of the Arduino UNO shield with its headers.....58
Figure 4.2 Installing X Axis and Y Axis Motors on the machine ...........................59
Figure 4.3 Control box .............................................................................................61
Figure 4.4 Installing the wires .................................................................................61
Figure 4.5 MACH3 Interface Breakout Board ........................................................62
Figure 4.6 Gear box and 3-phase induction motor ..................................................63
Figure 4.7 AC motor driver .....................................................................................63
Figure 4.8 AC motor control circuit ........................................................................64
Figure 4.9 Making a door for the speed control by Artelon ....................................64
Figure 4.10 Installing the new coupling with the steeper motor .............................65
Figure 4.11 Safe guard .............................................................................................65
Figure 4.12 Installing MACH3 board ......................................................................66
Figure 4.13 MACH3 Board .....................................................................................66
Figure 4.14 MACH3 Software .................................................................................67
Figure 4.15 Final shape of the machine ...................................................................67
Figure 4.16 Installing Mach3 program ....................................................................68
Figure 4.17 Location of software on PC ..................................................................68
Figure 4.18 Welcome screen....................................................................................69
Figure 4.19 License agreement ................................................................................69
Figure 4.20 Location of installation files of mach3 .................................................70
Figure 4.21 Selecting packages................................................................................70
Figure 4.22 Creating Turn Profile ............................................................................71
Figure 4.23 Giving name to turn profile ..................................................................71
Figure 4.24 Parallel port driver installation .............................................................72
Figure 4.25 Error message if parallel cable is not plugged .....................................72
Figure 4.26 Installation successful ...........................................................................73
Figure 4 27 Mach3 icons..........................................................................................73
Figure 4.28 Selecting Mach3Turn icon ...................................................................74
Figure 4.29 Mach3 Interface ....................................................................................74
Figure 4.30 Auto icon interface ...............................................................................75
Figure 4.31 Confirmation message of ending session .............................................75
Figure 4.32 Manual icon ..........................................................................................76
Figure 4.33 Manual Interface ...................................................................................76
Figure 4.34 Loading G-Code file .............................................................................77
Figure 4.35 Port & pin configuration .......................................................................77
Figure 4.36 Step pin & direction pin configuration .................................................78
Figure 4.37 Turning samples ...................................................................................78
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Figure 4.38 lathe machine samples ..........................................................................79
Figure 4.39 Sample configuration............................................................................79
Figure 4.40 Starting and stopping cycle, Editing G-Code .......................................80
Figure 4.41 Speed Control .......................................................................................80
Figure 4.42 Speed Control .......................................................................................81
Figure 4.43 Mach3 from windows 10 ......................................................................81
Figure 4.44 Mach3turn.............................................................................................82
Figure 4.45 Selecting Auto Icon ..............................................................................82
Figure 4.46 Mach3 software ....................................................................................83
Figure 4.47 Cycle Start ............................................................................................83
Figure 4.48 Appling the design in Mach3 software ................................................84
Figure 4.49 The work piece .....................................................................................86
Figure 4.50 Y-axis motor specifications ..................................................................95
Figure 4.51 X-axis motor specifications ..................................................................96
Figure 4.52 X-axis driver specifications and features .............................................97
Figure 4.53 Y axis motor driver specifications........................................................98
Figure 4.54 Spindle motor driver specifications ......................................................99
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Chapter 1. Introduction and theoretical framework
1.1 Introduction
CNC lathe machine and their prevalence are increasing because of the simplicity of
setting projects and their simplified functionality. The CNC operator should know
precisely what they are doing and should be experienced in the machine procedure.
Most lathe machine conversions will let both manual and CNC usefulness in the
machine so the client can pick which attribute to use at any given time. Most
conversions will yield a scaled down or little CNC machine that is usable at the
home or work shop level, yet still delivers a more prominent yield than manual
machines.(Reed, B). (2018, 4, 20).
Therefore, our research topic speaks about the conversion of lathe machines into
semi-automatic control lathe machine, demands two key elements, namely,
mechanical and electronics parts.
1.2 The benefits of Semi-Automatic CNC lathe machine
The conventional manual machines are very time consuming, has the manufacturer
to think and implement new methods to automate machines, by developing devices
with digital control system after World War II. These machines use digital control
perforated tape or punch cards to control the movement. In 1960, computers were
added to the machines that gave flexibility in process control and less time
consuming and cost effective with high productivity and accuracy, naming these
machines later using computer numerical control or CNC. Machines can be
controlled using a digital computer or accurately to replicate a series of operations
over and over again, and can produce the most complex pieces of the most skilled
professionals. (Lathe, 2018, 6, 27).
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1.3 The research aims
The aims of the research are to convert the conventional lathe machine into Semi-
Automatic CNC lathe machine. Thus eventually will improve the flexibility and
the accuracy of a traditional lathe machine by using 3 stepper motors with drivers
using GRBL coding and Arduino UNO kit. Also it will reduce the costs and time
by converting the available old lathe machine into more efficient machine in order
to help the small workshops owners in developing and rearranging their workshops
with minimized cost and maximized possible flexibility to return to the traditional
way.
1.4 The research SMART objectives
1.4.1 Selecting the PCB board the Electrical/Electronic PCB boards that will be
controlled by the computer within the Arduino UNO shield which will protect the
pins layout of Arduino. The dimensions of this design would be suitable so that
the dimensions are as follows (83.693 mm) width and (94.107mm) length, this
design idea with its structure is somewhat similar to the CNC work concept so
there will be a similarity between this design and CNC design, until this design is
achievable and implemented, it must uses the suitable software in the design so
that we can modify it immediately before execution if there is an error. Therefore,
software programs dedicated to design are very important before implementation,
since we are linked to a specific timetable, the design must be completed and
implemented from July 2017 to June 2018 as detailed in the following Gantt chart.
1.4.2 Software design engineering model to change the traditional lathe machine
into Semi-Automatic CNC machine using computer hardware and software. The
possibility of errors with high protection system for not causing damage on the
machine could be 10% in wires of USB connection. Achieving this goal will be by
start to test the PCB boards after the design by using “Proteus Design Suite”.
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The possibilities of making this goal is by design the ”PCB” control of CNC
lathe machine to control the machine by using GRBL software.
1.4.3 Motors specifications the electrical parts in CNC lathe machine such as
steeper motors, motors driver to control the machine in 2 axes easily and smoothly
without any errors, the movement of the 2 axes motors should have ±5% accuracy
to provide high efficiency of the production, the operation and the torque of the
motor would be suitable for the movement of 2 axes of the machine it is
approximately in range 9 to 45 kg.cm, to select the motor of the 2 axes we should
know the holding torque that needed to move the 2 axes smoothly and after that
select the motors according to the holding torque and select suitable stepper motor
drivers to control the motors accurately, using the knowledge that the researcher
get in his study in industry service complex in mechanical and electrical principles
subjects to select the motors and drivers, taking into consideration that the design
must be completed and implemented from July 2017 to June 2018 as detailed in
the following Gantt chart.
1.4.4 Power consumption versus Cost effective the electrical parts for not
consuming much power to prevent low operating cost in the project, the selection
of the electrical parts of the machine will consume less than 1200 watt, the
selection of the motors will be according to the needed power to control the 2 axes
of the machine, to select the motors it will use the knowledge that the researcher
get in his study in industry service complex in electrical power to choose the
motors to control the machine and use ram electronics and makers electronic to
choose between the available motors in the market.
1.4.5 Analyzing the PCB board and analyze the PCB board for CNC lathe
machine that will be inside the electrical box that will contain the electronic parts
like 2 drivers of steeper motors and Arduino UNO shield. It will be measured by
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produce an accurate PCB products that obtain the control to the machine with high
reliability.
The design will be achievable by designing the Electrical/Electronic circuits and
controls of the project with their PCB board by using “Altium Designer” Software.
And to be realistic this is the contribution of the knowledge that we gained from
“Technical vocational institute”, ”TVI” that helps and makes me design the PCB
boards like “Engineering Design”, ”Microprocessor”, ”Mechatronics System”,
”Health and Safety”, “Employability Skills”.
1.4.6 Electrical parts the electrical parts such as power supply , motors driver and
microcontroller in a suitable place to make it easy to control, design the suitable
box to contain the electrical parts; it will be 50 cm Length * 40 cm weight * 18 cm
depth or less, to design the control box to contain the electrical parts; the
researcher should measure the volume of the electrical parts and arrange it to be
suitable for the control box of the machine, use the knowledge that the researcher
had gained in industry service complex in measurement and engineering design
subject to design the control box.
1.4.7 Mechanical design and factor of safety the mechanical part such as two
stepper motors fixing or supporting, taking into consideration making a high factor
of safety in in the support of the motors to be safer something more making it
according to the stress analyses by using the solid works program, the all of this
point contribute the knowledge and information that the researcher gain from
"TVI" such as "Engineering design", "Mechanical principle, "Engineering
science", "Health and safety", hydraulic and pneumatic systems to design and
implement any mechanical part in the project.
1.4.8 Implement the mechanical parts and implement the mechanical parts like
speed control box and two stepper motors fixing and supporting by using the solid
works software and implement the motors fixing and installation the motors in the
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machine to make the machine controlled in (2) direction (X, Y) axes by this
motors.
1.4.9 Implementation of background knowledge will establish the mechanical
design and implementation all the mechanical parts of the project such as two
stepper motors fixing and making a factor of safety to be more safe and design the
speed control box for making a fall control about the speed of the motors "CNC
lath machine" are contributing the information that the researcher gain from
"TVI" like 3 "Engineering Design", "mechanical principle", "Engineering since
","Health and Safety", "Employability Skills", "Fluid mechanics" "hydraulic and
pneumatic "to design and implementation the mechanical part in the project
(CNC lathe Machine ) by using soled works & AutoCAD programs so it can
modify it before the execution because it might face several errors.
1.4.10 Software selection the lathe machine that will be controlled by using
GRBLGRU software within the Arduino UNO shield. The version of GRBLGRU
is 1.1 which contains more features than the previous version 1.0 like faster and it
is much easier than the old version. This software idea with its structure is
somewhat similar to the other CNC software concept so there will be a similarity
between this software and other CNC software. Until this design is achievable and
implemented, it’ll use the suitable software to control the machine so that we can
modify it before execution if there is an error. Therefore, software programs
dedicated to design are very important before implementation.
The research paper explains that the products can be produced by the modern
technology, which uses computer software, hardware and firmware in industries. It
is needed to use CNC lathe machine to get more accurate dimensions and irregular
shape. Along these CNC machines are becoming more important in modernized
industrialization and the developed design is successfully implemented in the
proposed work for the development of the lathe and use of proper process planning
for the development of the different components of the lathe attachment. Also
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CNC machine is based on the mechatronic controls and the computer interface
CAMSOFT. (Engineering, I. J. (2014).
Mr. Prakash N. Parmar, Prof. Vikas R. Gondalia, Prof. Niraj C. Mehta explains in
their paper the benefits of conversion the conventional lathe machines into semi-
automatic control lathe machine. (CNCLATHE 2014).
Since one of our aims is the benefits of converting conventional lathe machine into
semi-automatic control to increase the productivity in Egypt, we started looking for
everything related to CNC lathe machine.
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1.5.5 The importance of CNC manufacturing education to the economy
Maes, B. (2018).
Bert Maes explains in his paper that manufacturing work numbers drop in a lot of
countries. The low-skilled jobs are going off shore. However, the occupations that
need to be elevated levels of skills appear still to be here, as production in Europe
focuses on high value, technologically advanced products, giving good quality jobs
to increase the employment. ((Maes, B. (2009).
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is more accurate and cheap than the other types such as DC motors and DC servo
motors.
This research paper explains the software that can be used to control CNC lathe
machine using G-Code Interpreter – CAD/CAM, Parallel/Serial ports that sends
the signals out to drive the steeper motors and the machine as well and control it
from both directions and speed.
This research paper gives an explanation of software that can control CNC lathe
machine and it’s close to our software in our project and it is useful research that
gives an explanation of CAD/CAM software that can convert a “dxf, svg” file from
soildworks into the software. ((Engineering – Manual lathe to CNC Conversions (5
Jun. 2018)).
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1.5.11 CNCTURNING, CONDITION-BASED MAINTENANCE OF CNC
Srivastava, M. (2018). CONDITION-BASED MAINTENANCE OF CNC
TURNING MACHINE. [Online]. Available at:
http://www.ijmerr.com/uploadfile/2015/0409/201500.pdf [Accessed 22 May
2018].
Since one of our main problem is the unemployment and the lack of productivity in
CNC industry in Egypt, we started looking for everything related to CNC lathe
machine and we had a an important articles for the authors “Mayank Srivastava” in
his research paper. ((CNCTURNING. (2013).
This research paper is almost related to GRBLGRU software and XLoader and
Universal G-Code Sender in the project and it was beneficial to us to know the
platform that used to control CNC lathe machine.
The following table 1.1 explains a brief comparison between Altium Designer and
Proetus Design Suite which shows the advantages of both Altium Designer and
Proteus Design Suite and their disadvantages and the selection of the suitable one
in the project with examples and some schematics and Printed Circuit board design
to show some features of the 2 software.
Table 1.1 (Comparison between Altium Designer and Proetus Design Suite)
Altium Designer Proteus Design Suite
Advantages Advantages
Excellent component management Schematic capture
3D model of your board PCB Design
Import wizard to import from Orcad Simulation
Mentor and other software into Altium 3D visualization
Automated multi-channel layout and
routing
Disadvantages Disadvantages
Expensive User interface could have been made
Takes too much storage because of the better
libraries Plugs and errors in simulation
No simulation Simulation
Expensive
Source: Researcher
22
The following figure 1.1 below shows an example schematic circuit using Altium
Designer with 2 switches and 2 relays and 2 diodes and Vcc source and header for
motor and ULN to control the motor from both directions.
23
The following figure 1.2 below shows a sample Printed Circuit Board Circuit
Using Altium Designer 2017 to control bidirectional DC Motor.
Figure 1.2 (Printed Circuit Board Circuit Using Altium Designer 2017)
Source: Researcher
When it comes to the prices “Altium Designer” is the most expensive software
among the others because it costs “$7,245 USD” and Proteus costs “$6,592.00”
and Proteus Design Suite - have a simulation and can test any electronic circuits
which it can be better than “Altium Designer” because there’s no simulation in
Altium Designer but the fact is when it comes to “Proteus Design Suite” have bugs
and sometimes the connection of circuits is well designed but when the simulation
starts it has unknown problems but this software helps us to test the circuit before
printing and using it in our project.
24
The following figure 1.3 below shows a Schematic Circuit using Proteus Design
Suite 8 with 2 switches and 2 resistance and ULN and 2 relays with 2 diodes and
Direct Current motor.
Altium and Proteus, this software is important but Altium has its advantages in
PCB board, in fact Proteus Design Suite has also PCB board and 3d Visualization
as Altium.
The following figure 1.4 below shows a Printed Circuit board using Proteus Design
Suite 8. That used to control bidirectional dc motor.
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1.6.2 Mechanical Design
1) Auto Cad
As in mechanical design there will be use a lot of mechanical design software like
solidworks, AutoCAD, CATIA and Pro engineer…etc. and to make a mechanical
design for a stepper motors fixing and the speed control box, this is an important
point at the side of mechanical design in the project "CNC lathe Machine" The
researcher used two important mechanical design programs for designing the two
stepper motors fixing and the box of speed control and making a stress analyses to
this designs to be more suitable in the CNC lathe machine the researcher using two
programs are the solid works and AutoCAD.
Auto CAD (2014) is a drawing and designing software by using the computer that
supports the molding of 2D and 3D models and the system requirement about the
AutoCAD in figure 1.3 And the AutoCAD has an advantages and des advantages
followed in the table 1.2
Table 1.2: Advantages and disadvantages of Auto CAD program
AutoCAD
Advantages Disadvantages
Easy to use Expensive
Drawing and design 2D and 3D molds Need high-requirements computer
hardware
Suitable for a mechanical design or
Architectural Design
Source: Researcher
26
2) Soildworks
Solid works is software and soled molding computer-aided design (CAD) and
computer-aided engineering (CAE) computer program because it can make a 2D
and 3D design also it can make a stress analyses it is a computer aided engineering
(CAE) then it should use to make the important job system requirement about the
solid works program from (2011-2014) version in figure 1.4 And the solid works
has an advantages and des advantages followed in the table 1.3
All the these software has an advantages and disadvantages but solid works
program has an advantages which is more than the disadvantages because the
important point in this program is supporting the simulation option that can make
the designer has a lot of information about the design Second, point this software
support the stress analyses option in it that make the designer knew the weakness
point in the design, something more in it can choose the suitable material to de the
design like wood, metal etc. Something more this program has a huge mechanical
library like a gears and screw and more and more standard mechanical part and
Stuff like that and that is a good point to the designer.
27
1.6.5 Software
Grbl is a no-compromise, high performance, low cost alternative to parallel-port-
based motion control for CNC lathe and milling machines and Grbl runs on
Arduino with a 328p processor (Uno) so the controller is written in highly
optimized C utilizing every clever feature of the AVR-chips to achieve precise
timing and asynchronous operation. (GitHub. Accessed 5 Jun. 2018)
28
1.7 Time and budget
1.7.1 Budget
The following table 1.5 below shows the budget list that used in the project with
the total amount of the mechanical and electronic parts which in terms of
availability of funds and in terms of trying to reduce the cost, the project costs in
general 10000 EGP.
Table 1.5 (The project budget list)
Attribute Name Number of pieces Price Total Price
(EGP) (EGP)
Copper Board 2 60 120
Acid 1 15 15
Stickers 2 5 10
Header 6 30 180
CNC Shield 1 150 150
Rosetta 20 15 300
Wire (5 m) 20 17.5 350
Connector 4pin 3 40 120
Fan 2 30 60
Limit Switch 4 5 20
Electronic Parts
Terminal block 1 15 15
Stepper motor 1 380 380
Paper A4 15 15 225
Power cable 1 15 15
Spacer 10 30 300
Heat shrink 6m 10 24 240
Connector 6pin 2 12 24
Socket Arduino 1 3 3
Power socket 1 5 5
Switch on/off 1 35 35
CNC shield 1 150 150
AC driver 1 5000 5000
Tools 45 45
Transportation 430 430
Total 6588
The
percentage of 65.88 %
electrical parts
29
Table 1.5 (Continue)
Spray paint 2 15 30
Lock for the box 1 10 10
Mechanical parts
Door hinges 2 12 24
Bolt 20 2 40
Nut 20 2 40
Washer 40 1 40
Flat steel sheet Dimension 200 200
(100*90)cm
Total 384
The percentage
of mechanical 3.84 %
parts
Source: Researcher
30
1.7.2 Time
The following figure 1.5 shows the Gantt chart of the project since we are attached
to a schedule from July 2017 to June 2018.
31
Chapter 2. Safety and Risk Assessment
In the following table 2.1 below shows the risk assessment of mechanical parts in the project.
Likeliho
Severity
Who might be harmed Safety precautions
Rating
Risk
Risk
Risk
Hazards List
od
and how? and control measures
Medium 2
Medium 4
Serious 2
box he use drill and that health and safety
Entanglement
may entangle with the instructions from the
unsuitable closes and supervisor in the
cause injury to him work place
The researcher
should follow the
The researcher, during
health and safety
working on mechanical
Medium 2
Medium 4
instruction from the
Serious 2
The researcher
The researcher, his should follow the
body may friction with health and safety
Medium 2
Medium 4
Serious 2
Source: Researcher
32
In the following table 2.2 below shows the risk assessment of electrical parts in the project.
Likeliho
Severity
Who might be harmed Safety precautions
Rating
Risk
Risk
Risk
Hazards List
od
and how? and control measures
The researcher
The researcher during should follow the
the implementation of health and safety
Electrical
the project he use
Medium 2
Medium 4
Serious 2
instruction from the
portable tools and portable tools and supervisor in the
equipment equipment such as drill work place and make
and power supply it sure the equipment
may cause shock to him wires is isolated
correctly
Source: Researcher
In the following table 2.3 below shows the risk assessment of chemical risks in the project.
Risk
Risk
Hazards List
od
The researcher
The researcher while should use the fans or
Medium 2
Medium 4
Serious 2
Low 2
Corrosive
iron chloride and it may especially gloves
touch his skin and cause
skin diseases
Source: Researcher
33
Chapter 3. Project implementation
3.1 Implementation
In order to make the implementation of the project, we consider our aim of the
research project which is to convert the manual lathe machine into semi-automatic
CNC lathe machine to improve the flexibility and the accuracy of a traditional
lathe machine by using 2 stepper motors with drivers using GRBL software and
Altium Designer to design the Electronic PCB boards which is Arduino UNO
shield that will be controlled by the computer.
The following table 3.1 below shows the actual specifications for Arduino UNO
shield according to British standards.
Location
Interface Environment Ergonomics
Easy to install Vibration Using sound level meter
Operation
Safety Timing Training
British standards Duration ( 4 days ) Skilled operator
Source: Researcher
34
3.2.1 Steps for Electrical/Electronic design
The following figure 3.1 shows the schematic circuit of Arduino UNO shield using
9 headers.
The following figure 3.2 shows the PCB designing steps on the software.
Figure 3.2 (Printed Circuit Board 2D layout for Arduino UNO Shield)
Source: By the researcher
35
The following figure 3.3 shows the PCB “Printed circuit board” 2D layout of
Arduino UNO shield with its dimensions.
Figure 3.3 (Printed Circuit Board 2D layout for Arduino UNO Shield)
Source: By the researcher
The following figure 3.4 shows the printing steps of the PCB for Arduino UNO
shield before start cutting the copper.
Figure 3.4 (The printing steps of the PCB for Arduino UNO)
Source: By the researcher
36
The following figure 3.5 shows the final form of PCB of the Arduino UNO shield
with its headers.
The following figure 3.6 shows the MACH3 Interface Breakout Board CNC
that we used instead of using Arduino UNO kit with its shield because it is not
compatible with GRBL software and it can’t control the 2 directions and speed of
the 2 steeper motors.
37
The following table 3.2 shows the specifications of the new board which will be
used to control the 2 directions and speed of steeper motor instead of using
Arduino UNO kit with its shield because it wasn’t compatible with GRBL and
Universal G-Code Sender software.
Compatible
Input Power Stepper Motor Driver type Total Weight Dimensions
Driver
USB port to Max 52-phase
directly get Microstep Pulse and Approx. 75g 90 mm Length
power from PC controllers and Direction signal 70 mm Width
and 12-24V MACH3 control 20 mm Height
power software
supply(optional)
The following figure 3.13 shows Mach3 board that we used as an alternative
because it is specially designed for the CNC stepper motor driver controller, such
as M542, M542H, MA860H, 2M542, 2M982, DM542(A), DM860(A) etc. single
axis stepper driver controller series. With this this board can be directly controlled
by the PC via the MACH3, EMC2, KCAM4.
The following table below 3.3 shows the technical specifications of the electronic
equipment that used in the project.
38
Table 3.3 (Specifications)
Source: Researcher
39
Figure 3.7 shows sorting the electronic component inside the control box.
Figure 3.8 shows making holes inside the control box for installing the fans.
40
Figure 3.9 shows installing emergency stop inside the control box.
Figure 3.10 shows installing the AC Power Connector with Fuse Compartment
inside the control box to protect the electronic equipment.
41
Figure 3.11 shows installing the circuit board of LCD and Mach3 and Step-Down
Voltage.
42
3.2.4 Selection criteria of the X and Y axis motors
There are important criteria the researcher puts when it comes to select the X and
Y axis motor which are the torque of the motors, the accuracy of the motors, the
power consumption of each motor and finally the cost of each motor, after the
researcher put the selection criteria of the X and Y axis motor there are alternatives
that do the same function and can use them in the project which are DC motor, DC
servo motor and stepper motor but each has advantages and disadvantages and that
shows below in table 3.4 and table 3.5 and table 3.6.
43
To know the best selection of the X and Y axis motor the researcher makes a
decision making to know which motor will be used in the project and that shows in
the below table 3.5 and chart which shows a chart of the comparasion
specifications of the X/Y axis steeper motors.
Alternative Comparasion
35
30
25
20
15
10
5
0
Accuracy Torque Power consumption Cost Total
Source: Researcher
44
The researcher have chosen the stepper motor over the DC motor and DC servo
motor because it has low cost compare to the other motors and it has high starting
torque and that is important to be able to move the carriage of the machine and
because the environment of the project is hard and it has high temperature.
To control the X and Y axis stepper motor and because it needs a dedicated control
circuit the researcher gets a motor driver to each one of the two motor to be able to
control them, the criteria to choose the motor driver is the output current and it
must be suitable for the X and Y motors and it shows in the specifications of the X
and Y axis motors in appendix 1 for the X axis motor and appendix 2 for the Y
axis motor, the supply voltage it need to start working and finally the working
temperature the motor drivers can work in because the environment of the project
it has high temperature, after the researcher put the selection criteria, there are
alternatives models of the X and Y axis motor driver that do the same function and
can use them in the project which are TB6600 stepper motor driver and TB6560
stepper motor driver and that for control the Y axis motor but each one has
different parameters and that shows in table 2.3.
45
The researcher have chosen the motor driver model TB6600 because it has more
feature than the TB6560 model which it has output current 0.5 to 4 A and that is
more suitable to the motor that uses in the project to move the Y axis, it has
suitable working temperature and it also has heat sink that for cooling the driver
down when it gets high temperature though the cost of the chosen driver it is
higher the other but it has more feature then the other or in anther words it has cost
effective.
The model motor driver of X axis is DM860 and the researcher choose it because it
more suitable for the X axis motor and it can control the motor with high efficient
such as in table 3.7 shows the working temperature is suitable for the environment
of the project because it has high temperature and the output current suitable for
the current of X axis motor.
Working voltage 24 to 80 V
Cost 1000 LE
Source: Researcher
The specification of the stepper motor driver DM860 that uses to move the X axis
in appendix 3 and the specification of the stepper motor driver TB6600 that use to
move the Y axis in appendix 4.
46
3.2.6 Selection criteria of spindle motor driver
To be able to convert the manual lathe into semi-automatic lathe machine the
researcher consider that the control is the most important part of the machine
which is spindle motor by the AC motor driver and the selection criteria to choose
this driver are the output current of the motor driver should be suitable to the
spindle motor and the output voltage of the motor driver should be suitable to the
spindle motor and the safety of the motor driver if it has over current production or
not, before the researcher choose the spindle motor driver it should consider the
specifications of the spindle motor which are the model number which is
VMA534PDB233 , the RPM of the spindle motor which is 425 rev/min, the
voltage in condition star connection which is 380/440 V, the current in star
connection which is 1.2 A, the voltage in condition Delta connection which is
220/250 V, the current in Delta connection which is 2.1 A, finally after the
researcher put the selection criteria of the motor driver and know the specifications
of the spindle motor, the researcher choose the best motor driver in the marker
which is APP type and the model number is ACS355. The reasons the researcher
choose this type because it has many features which are the output current is 3.2
which is suitable of the spindle motor in the project, it has easy control interface
which shows in figure 3.27 and it is easy to control the speed of the spindle motor
from it, it has over current protection which is the circuit diagram of the spindle
motor driver that will shows in appendix 5.
While also the AC Driver Motor is used in many other applications ranging from
small appliances to large compressors. About 25% of the world's electrical energy
is consumed by electric motors in industrial applications, which can be more
efficient when using VFDs in centrifugal load service.
47
The implementer should use the electrical equipment to help him in the project
implementation, the researcher used the following tools in the electrical
implementation which it shows in figure 3.13and they are heat gun, screw driver
which is used for install and uninstall the electrical equipment in the project.
48
Connecting the stepper motor driver to Mach 3 circuit by using the connecting
diagram which it shows in figure 3.15.
49
After the researcher finished the connection in the control box he starts to install
the spindle motor driver in the special box to be protected from any damage that
could happen to in which it shows in figure 3.16.
The speed control box use to make housing to the speed control to make a control
in the speed of the motor and dispense about the gearbox of the manual lathe
machine and make it semi CNC lathe machine.
These designs below in figure 3.19 are for the 2 steeper motors instillation, makes
these designs by using solid works program and making a stress analyses to make
sure of the weight of the motors.
51
In addition, choosing the suitable material, these supports used for making an
installation for the stepper motors in two directions (X, Y) axis.
52
3.3. 2 Steps for mechanical implementation
To implement all of these components that designed by using solid works software
and before starting to impellent the mechanical parts in the work shop it we
consider the personal protective equipment related to safety because the safety is
first of all and that shown in the below figure 3.21.
53
The following figure 3.23 below shows the equipment’s that used during the
mechanical implementation step which are Screwdrivers, Drill, and Circular Saw.
After installing the coupling, we install the stepper motors in the machine one
work in (X) axis and another one work in the (Y) axis that will be working with
high efficiency and saving time and money that shows in the below figure 3.43.
54
The following figure 3.25 below shows the safety signs that we putted on the
machine to worn the operator from any spare parts or dangerous equipment.
The following figure 3.26 shows the safety signs on the machine to worn the
operator from the rubbish or any spare parts.
55
3.4) Software and control
Since the aim of the research project is to convert the manual lathe into Semi-
Automatic CNC lathe machine to improve the flexibility and the accuracy of a
traditional lathe machine by using 3 stepper motors with drivers using GRBLGRU
with Universal G-Code sender and X-Loader in order to control 3 stepper motors
(axis x, y and z), we selected the free source GRBLGRU software to control the
machine by Arduino UNO and control the 2 directions of steeper motors with their
speed.
The following figure 3.27 shows GRBLGRU software that used to control the
control box with its Arduino UNO to control the 2 steeper motors.
56
The following figure 3.28 below shows Universal G-Code sender software that
used to with GRBL software because it is compatible and cross platform with G-
Code sender and it used for interfacing with advanced CNC controllers and control
the machine by sending a design which is (dxf file) from Soildworks design.
The following figure 3.29 below shows the X-Loader software that used with
GRBL and Universal G-Code sender to upload a compiled Arduino UNO sketch
(HEX file) without using the Arduino integrated development environment.
57
Chapter 4. Project Evaluation and final result
4.1 Introduction
Figure 4.1 (The final form of PCB of the Arduino UNO shield with its
headers)
Source: By the researcher
58
In the project planning the researcher put the aim and smart objectives to be
archived after finish the implementation of the project one of these objectives is
select the electrical parts to control the machine in two direction which are X axis
and Y axis direction by using two suitable motors with suitable torque to be able to
move the machine easily without any problem that could happen during the work
of the machine and suitable drivers to be able to control the two motors and this
objectives had been achieved correctly and the selected motor able to control the
machine in the two direction easily, the researcher had selected two stepper motor
one of them has torque 45 Kg.cm to move the machine in X axis direction and the
other has torque 9 Kg.cm to move the machine in Y axis direction and suitable
drivers to control each stepper motor correctly in figure 3.1 shows the two motor
installed on the machine to control it in the X and Y axis direction. But the selected
X axis motor has a problem which is during working time of the machine the
motor gets high temperature and that problem should be solve to make the machine
work correctly without any fails in the electrical parts as it shows in the following
figure 4.2.
59
The 2nd objective the researcher put was to select electrical parts such as motor,
driver and controller with low power consumption to prevent low operation cost of
the lathe machine and not be higher than 1200 watt after the researcher had
selected the all the electrical part this objective has applied successfully because
power consumption of all the electrical parts is from minimum 900 watt to
maximum 1000 watt and that shows in table 4.1.
Source: Researcher
60
The 3rd objective the researcher put was install the electrical parts of the lathe
machine without making any obstacles that could happen to the movement of the
machine in X axis or Y axis or the spindle motor and this objective has applied
successfully by install the electrical parts in a special box to avoid any damages
that could happen to the electrical parts as it shows in figure 4.3.
Install the wire of the motor that install on the machine in special cases as it shows
in figure 4.4.
61
4.3 Second evaluation stage
The following figure 4.5 shows the MACH3 Interface Breakout Board that we
used instead of using Arduino UNO kit with its shield because it is not compatible
with GRBL software and it can’t control the 2 directions and speed of the 2 steeper
motors.
The following table 4.2 shows the specifications of the new board which will be
used to control the 2 directions and speed of steeper motors instead of using
Arduino UNO kit with its shield because it wasn’t compatible with GRBL and
Universal G-Code Sender software.
The researcher choose AC motor driver ABB type with easy control panel
interface which is shows in figure 3.7 and it is combatable with the spindle motor
driver because the current of the spindle motor is 2.1 A and the current that the
driver can control it is 3.4 A.
The researcher changed the wood door of the box to be clearer; the following
figure 4.9 shows the change process of the speed control wood door it by Artelon
by using the CNC rotter machine.
64
The coupling in the project prototype are used to transferring the motion of the
stepper motors into the machine it is the important point that we are used it but we
change it to the perfect one to be more suitable and more compatible with the
stepper motors that shows in the below figure 4.10.
Figure 4.10 (Installing the new coupling with the steeper motor)
Source: Researcher
The following figure 4.11 shows the new safe guard to protect the machine and the
worker from rubbish because it is an important point in the machine to be safer for
the users.
65
4.4 Final evaluation stage
The following figure 4.12 shows the installation process of “MACH3 board” that
will be installed inside the control box.
After doing the modifications for the machine and installing all the Electrical and
Mechanical components, Mach3 interface breakout board is the suitable board that
used instead of Arduino UNO, and it controlled the speed and directions of the 2
steeper motors and we made testing for the motors in “Mach3” software and the
machine worked with the new board in the following figure 4.13 below.
MACH3
Board
66
The following figure 4.14 shows the alternative software that the researcher used
instead of GRBLGRU as it mentioned above and the alternative is “MACH3
software” that is compatible with any CNC in general and specially “Milling” and
“Lathe/Turning” machines.
The following figure 4.15 shows the final shape of the Semi-Automatic Lathe
machine after doing all the modifications from the Electrical/Electronic and
Mechanical and software/control sides.
67
4.5 MACH3 manual to control the lathe machine automatically
The following figure 4.17 shows how to find software after downloading it
(location of software)
68
The following figure 4.18 shows the first screen of software (welcome screen)
69
The following figure 4.20 shows location of installation files of mach3.
The following figure 4.23 shows how to give a name to turn profile.
The following figure 4.25 shows message error if parallel cable is not plugged.
73
The following figure 4.28 shows selecting icon to open program
74
The following figure 4.30 shows Auto icon interface
The following figure 4.35 shows how to configure ports & pins
77
The following figure 4.36 shows Step pin & direction pin configuration
The following figure 4.37 shows lathe turning wizards (Turn samples)
80
4) Change the speed of spindle motor up and down to be suitable with the work
piece by using the arrows shown in the below picture:
81
6) Select Mach3Turn from menu as shown in the below figure 4.44
4.7.1 Conclusion
After the researcher finished the electrical and mechanical implementation and had
chosen the suitable software to control the machine. This is the final test of the
machine to know if it meets the aim and objective of the project such as
repeatability and accuracy of the work piece or not in the below figure 4.48 that
shows the design of the work piece that the machine did while working.
Source: Researcher
84
After applying the 2 samples of the design that shown in figure 4.49, the result and
the measurement of the 2 samples compare to the design on the Mach3 software
shown in the below table 4.3.
From the table 4.3 the difference between the measurement of the 2-samples and
the design on Mach3 software, each sample has varied amount of error percentage
in the measurement of the diameter and length of the work piece and that happened
because of different reasons such as the mechanical parts of the lathe machine is
not work efficiently or the setup of the zero X and zero Z of the work piece is
different and that could effect on the measurement of the work piece.
After the researcher had tested the repeatability and the accuracy of the work piece
that operate by semi-automatic lathe machine, in figure 4.49 blow that shows the
next design on Mach3 software to apply it by the semi-automatic lathe machine
and apply it too by manual lathe machine to know the difference between the
measurement of the 2 work pieces and decide which machine will apply the design
correctly.
85
Figure 4.49 (The work piece)
Source: Researcher
After the manual lathe and semi-automatic lathe machine had finished the two
samples, the result and the measurement of the 2 samples compare to the design on
the Mach3 software shown in table 4.4.
86
From table 4.4, the measurement of the two work pieces shows there are difference
between the manual and semi-automatic lathe machine and shows the manual lathe
machine is better from the semi-automatic lathe machine and that happened
because of different reasons such as the mechanical parts of the lathe machine is
not work efficiently or the setup of the zero X and zero Z of the work piece is
different and that could effect of the measurement of the work piece as it shows in
table 4.3 but the time consumption of the semi-automatic lathe machine is lower
than the time consumption of the manual lathe machine and that means if the
researcher solve the 2 reasons above the semi-automatic lathe machine will be
more efficient and better than the manual lathe.
The evaluation of the project considered successful since the objectives are met
and the expenses are not too high. The stepper motors used are of top quality and
they performed very well and accurately. As for the Mach3 board worked very
stable and good micro stepping features with such a high current driving capability
for the steeper motors while in this project there are aims and objectives that
should be achieved after finishing the project implementation and that objectives
has been achieved successfully although there were some problem during the
electrical implementation but the researcher found out the best solution on these
problems to make the project work correctly and efficiently without any fails.
87
4.7.2 Future work
88
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94
4.7 Appendices
4.7.1 Appendix A: Y axis stepper motor specifications model 86HZ118-85
95
4.7.2 Appendix B: X axis stepper motor specifications model 57HZ56630
96
4.7.3 Appendix C: X axis motor driver specifications and features model TB6600
97
4.7.4 Appendix D: Y axis motor driver specifications model DM860
98
4.7.5 Appendix E: Spindle motor driver ABB type model ASC355
99
1