Mini Milling Cnc Machine.docx

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Table of Contents Contents

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Chapter 1 Introduction …........................................................................................................................... 2 Preliminary ....................................................................................................................... 2 Background .......................................................................................................................3 Problem statement ............................................................................................................ 4 Objective .......................................................................................................................... 4 Scope................................................................................................................................. 4 Impact ............................................................................................................................... 4 Chapter 2 Literature review........................................................................................................................ 5 Preliminary .......................................................................................................................5 Sejarah plotter ............................................................................................................ 6 Reka bentuk (A, B, C) ...............................................................................................7 Inovasi plotter (A, B, C) ................................................................................10 Pengujian.................................................................................................. 11 Proses otak& software ........................................................................................ 12 Chapter 3 Methodology ................................................................................................................... 12 Preliminary ............................................................................................................. 15 Flow Chart .......................................................................................................... 16 Development process ........................................................................................ 17 (mesin,kimpal,sambungan,lukisan,inventor) .................................................. 17 Standard test......................................................................................... 18 Chapter 4-Design research .................................................................................... 19 Inventor ...................................................................................................................... 20 Harga bahan ..................................................................................................... 21 Breakout Board ................................................................................................................................. 22

2 Bab 5-Dapatan Kajian ........................................................................................................................... 23 Rekabentuk ....................................................................................................................................... 24 Inovasi ............................................................................................................................................... 24 Proses ................................................................................................................................................ 25 Pengujian Data .................................................................................................................................. 26 Bab 6-Perbincangan .............................................................................................................................. 27 Rekabentuk ....................................................................................................................................... 28 Inovasi ............................................................................................................................................... 28 Proses ................................................................................................................................................ 29 Pengujian Data .................................................................................................................................. 30 Bab 7-Kesimpulan ................................................................................................................................ 31 Cadangan........................................................................................................................................... 32 Bab 8-RujuKan ..................................................................................................................................... 33 Bab 9-Lampiran .................................................................................................................................... 34

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CHAPTER 1 - INTRODUCTION

PRELIMINARY

Computer numerical control (CNC) is the automation of machine tools by means of computers executing pre-programmed sequences of machine control commands. This is in contrast to machines that are manually controlled by hand wheels or levers, or mechanically automated by cams alone. In modern CNC systems, the design of a mechanical part and its manufacturing program is highly automated. The part's mechanical dimensions are defined using computer-aided design (CAD) software, and then translated into manufacturing directives by computer-aided manufacturing (CAM) software. The resulting directives are transformed (by "post processor" software) into the specific commands necessary for a particular machine to produce the component, and then are loaded into the CNC machine. Since any particular component might require the use of a number of different tools – drills, saws, etc. Modern machines often combine multiple tools into a single "cell". In other installations, a number of different machines are used with an external controller and human or robotic operators that move the component from machine to machine. In either case, the series of steps needed to produce any part is highly automated and produces a part that closely matches the original CAD. For example, milling machine, drilling machine, EDM, turning machine, wire cut machine, and more. All this machine can be find in engineering and manufacturing industry. In general, CNC Machine are bigger than manual machine and it cost a lot of working space and high in maintenance cost and because of this reason a research has been carry out to solve the problem for the small and medium industry facing. This research is conducted to design and create a Mini CNC Milling machine that is low in maintenance and consume less working space.

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BACKGROUND

The history of numerical control (NC) began when the automation of machine tools first incorporated concepts of abstractly programmable logic, and it continues today with the ongoing evolution of computer numerical control (CNC) technology. The first NC machines were built in the 1940s and 1950s, based on existing tools that were modified with motors that moved the controls to follow points fed into the system on punched tape. These early servomechanisms were rapidly augmented with analogy and digital computers, creating the modern CNC machine tools that have revolutionized the machining process. The first CNC machines were developed in the 1940s and 50s and relied on a common telecommunication data storage technology known as “punched tape” or “perforated paper tape.” Punched tape technology is long obsolete as the data medium quickly transitioned to analogy and then digital computer processing in the 1950s and 1960s. Machining in general is a way to transform a stock piece of material such as a block of plastic and arrive at a finished product (typically a prototype part) by means of a controlled material removal process. Similar to the other prototype development technology, FDM (3D printing), CNC relies on digital instructions from a Computer Aided Manufacturing (CAM) or Computer Aided Design (CAD) file like Solid works 3D. The CNC machine interprets the design as instructions for cutting prototype parts. The ability to program computer devices to control machine tools rapidly advances shop productivity by automating the highly technical and labour intensive processes. Automated cuts improve both the speed and the accuracy with which prototype parts can be created - especially when the material is critical (such as is the case with polypropylene. Oftentimes machining processes require the use of multiple tools to make the desired cuts (e.g. different sized drill bits). CNC machines commonly combine tools into common units or cells from which the machine can draw. Basic machines move in one or two axes while advanced machines move laterally in the x, y axis, longitudinally in the z axis, and oftentimes rotationally about one or more axes. Multi axis machines are capable of flipping parts over automatically, allowing you to remove material that was previously “underneath.” This eliminates the need for workers to flip the prototype stock material and allows you to cut all sides without the need for manual intervention. Fully automated cuts are generally more accurate than what is possible with manual inputs. That said, sometimes finishing work like etching is better accomplished by hand as well as simple cuts that would require extensive design work to program the machine for automation.

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PROBLEM STATEMENTS 1. The price for CNC Milling machine at market is high 2. The size and weight of CNC Milling machine at market is big

OBJECTIVE To create and design a Mini model of CNC Milling Machine.

SCOPE

This scope will include area Department of Mechanical Engineering Polytechnic Merlimau which has population of mechanical student and other instructor. Specification: 1.

Low price material and component a

Wood

b

DIY Rail Way

c

DIY Roller for Belt system

d

Small Stepper motor

2.

Estimated size 50 cm x 60cm

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Weight Less than 20kg

Impact

1. Polytechnic engineering student can use this machine for learning purposes

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Chapter 2- LITERATURE REVIEW

PRELIMINARY

The first NC machines were built in the 1940s and 1950s, based on existing tools that were modified with motors that moved the controls to follow points fed into the system on punched tape. These early servomechanisms were rapidly augmented with analogy and digital computers, creating the modern CNC machine tools that have revolutionized machining processes.

HISTORY OF CNC CNC means Computer Numerical Control. This means a computer converts the design produced by Computer Aided Design software (CAD), into numbers. The numbers can be considered to be the coordinates of a graph and they control the movement of the cutter. In this way the computer controls the cutting and shaping of the material. CNC machines typically fall into one the two general categories: conventional machining technologies and novel machining technology 1. Conventional Technologies: a. Drills: i. Drills work by spinning a drill bit and moving the bit about and into contact with a stationary block of stock material. b. Lathes: i. Lathes, very much the inverse of drills, spin the block of material against the drill bit (instead of spinning the drill bit and putting it into contact with the material). Lathes typically make contact with the material by laterally moving a cutting tool until it progressively touches the spinning material.

c. Milling Machines: i. milling machines are probably the most common CNC machine in use today. They involve the use of rotary cutting tools to remove material from the stock unit.

7 2. Novel Technologies: a. Electrical and/or Chemical Machining: i. There are a number of novel technologies that use specialized techniques to cut material. Examples include Electron Beam Machining, Electrochemical machining, Electrical Discharge Machining (EDM), Photochemical machining, and Ultrasonic machining. Most of these technologies are highly specialized and are used in special cases for mass-production involving a particular type of material. b. Other Cutting Mediums: i. There are a number of other novel technologies that use different mediums to cut material. Examples include laser cutting machines, oxy-fuel cutting machines, plasma cutting machines, and water-jet cutting technology.

There are several types of program uses to associated with CNC

Cams The automation of machine tool control began in the 19th century with cams that "played" a machine tool in the way that cams had long been playing musical boxes or operating elaborate cuckoo clocks. Thomas Blanchard built his gun-copying lathes (1820s–30s), and the work of people such as Christopher Miner Spencer developed the turret lathe into the screw machine (1870s). Cam-based automation had already reached a highly advanced state by World War I (1910s). However, automation via cams is fundamentally different from numerical control because it cannot be abstractly programmed. Cams can encode information, but getting the information from the abstract level (engineering drawing, CAD model, or other design intent) into the cam is a manual process that requires machining or filing. In contrast, numerical control allows information to be transferred from design intent to machine control using abstractions such as numbers and programming languages. Various forms of abstractly programmable control had existed during the 19th century: those of the Jacquard loom, player pianos, and mechanical computers pioneered by Charles Babbage and others. These developments had the potential for convergence with the automation of machine tool control starting in that century, but the convergence did not happen until many decades later.

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Tracer control The application of hydraulics to cam-based automation resulted in tracing machines that used a stylus to trace a template, such as the enormous Pratt & Whitney "Keller Machine", which could copy templates several feet across. Another approach was "record and playback", pioneered at General Motors (GM) in the 1950s, which used a storage system to record the movements of a human machinist, and then play them back on demand. Analogous systems are common even today, notably the "teaching lathe" which gives new machinists a hands-on feel for the process. None of these were numerically programmable, however, and required an experienced machinist at some point in the process, because the "programming" was physical rather than numerical.

Servos and Selsyn One barrier to complete automation was the required tolerances of the machining process, which are routinely on the order of thousandths of an inch. Although connecting some sort of control to a storage device like punched cards was easy, ensuring that the controls were moved to the correct position with the required accuracy was another issue. The movement of the tool resulted in varying forces on the controls that would mean a linear input would not result in linear tool motion. In other words, a control such as that of the Jacquard loom could not work on machine tools because its movements were not strong enough; the metal being cut "fought back" against it with more force than the control could properly counteract. The key development in this area was the introduction of the servomechanism, which produced powerful, controlled movement, with highly accurate measurement information. Attaching two servos together produced a selsyn, where a remote servo's motions were accurately matched by another. Using a variety of mechanical or electrical systems, the output of the selsyn could be read to ensure proper movement had occurred (in other words, forming a closed-loop control system). The first serious suggestion that selsyn could be used for machining control was made by Ernst F. W. Alexanderson, a Swedish immigrant to the U.S. working at General Electric (GE). Alexanderson had worked on the problem of torque amplification that allowed the small output of a mechanical computer to drive very large motors, which GE used as part of a larger gun laying system for US Navy ships. Like machining, gun laying requires very high accuracy – fractions of a degree – and the forces during the motion of the gun turrets was non-linear. In November 1931 Alexanderson suggested to the Industrial Engineering Department that the same

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systems could be used to drive the inputs of machine tools, allowing it to follow the outline of a template without the strong physical contact needed by existing tools like the Keller Machine. He stated that it was a "matter of straight engineering development". However, the concept was ahead of its time from a business development perspective, and GE did not take the matter seriously until years later, when others had pioneered the field.

CNC IMPORTANT REVOLUTION

Many of the commands for the experimental parts were programmed "by hand" to produce the punch tapes that were used as input. During the development of Whirlwind, MIT's real-time computer, John Runyon coded a number of subroutines to produce these tapes under computer control. Users could enter a list of points and speeds, and the program would calculate the points needed and automatically generate the punch tape. In one instance, this process reduced the time required to produce the instruction list and mill the part from 8 hours to 15 minutes. This led to a proposal to the Air Force to produce a generalized "programming" language for numerical control, which was accepted in June 1956. Doug Ross was given leadership of the project and was made head of another newly created MIT research department. He chose to name the unit the Computer Applications Group feeling the word "application" fit with the vision that general purpose machines could be "programmed" to fill many roles. Starting in September, Ross and Pople outlined a language for machine control that was based on points and lines, developing this over several years into the APT programming language. In 1957 the Aircraft Industries Association (AIA) and Air Material Command at Wright-Patterson Air Force Base joined with MIT to standardize this work and produce a fully computer-controlled NC system. On 25 February 1959 the combined team held a press conference showing the results, including a 3D machined aluminium ash tray that was handed out in the press kit. In 1959 they also described the use of APT on a 60-foot mill at Boeing since 1957.Meanwhile, Patrick Hanratty was making similar developments at GE as part of their partnership with G&L on the Numericord. His language, PRONTO, beat APT into commercial use when it was released in 1958. Hanratty then went on to develop MICR magnetic ink characters that were used in cheque processing, before moving to General Motors to work on the ground-breaking DAC-1 CAD system.

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APT was soon extended to include "real" curves in 2D-APT-II. With its release into the Public Domain, MIT reduced its focus on NC as it moved into CAD experiments. APT development was picked up with the AIA in San Diego, and in 1962, by Illinois Institute of Technology Research. Work on making APT an international standard started in 1963 under USASI X3.4.7, but any manufacturers of NC machines were free to add their own one-off additions (like PRONTO), so standardization was not completed until 1968, when there were 25 optional add-ins to the basic system. Just as APT was being released in the early 1960s, a second generation of lower-cost transistorized computers was hitting the market that were able to process much larger volumes of information in production settings. This reduced the cost of programming for NC machines and by the mid-1960s, APT runs accounted for a third of all computer time at large aviation firms.

CADCAM meets CNC

While the Servomechanisms Lab was in the process of developing their first mill, in 1953, MIT's Mechanical Engineering Department dropped the requirement that undergraduates take courses in drawing. The instructors formerly teaching these programs were merged into the Design Division, where an informal discussion of computerized design started. Meanwhile, the Electronic Systems Laboratory, the newly rechristened Servomechanisms Laboratory, had been discussing whether or not design would ever start with paper diagrams in the future. In January 1959, an informal meeting was held involving individuals from both the Electronic Systems Laboratory and the Mechanical Engineering Department's Design Division. Formal meetings followed in April and May, which resulted in the "Computer-Aided Design Project". In December 1959, the Air Force issued a one-year contract to ESL for $223,000 to fund the project, including $20,800 earmarked for 104 hours of computer time at $200 per hour. This proved to be far too little for the ambitious program they had in mind. In 1959 that was a lot of money. Newly graduated engineers were making perhaps $500 to $600 per month at the time. To augment the Air Force's commitment Ross replayed the success of the APT development model. The AED Cooperative Program which ultimately ran for a five-year period had outside corporate staff, deeply experienced design manpower on loan from companies. Some relocating to MIT for half a year to 14 or 18 months at a time. Ross later estimated this value at almost six million dollars in support of AED development work, systems research, compilers. AED was a

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machine independent software engineering job and an extension of ALGOL 60 the standard for the publication of algorithms by research computer scientists. Development started out in parallel on the IBM 709 and the TX-0 which later enabled projects to run at various sites. The engineering calculation and systems development system, AED, was released to the Public Domain in March 1965. In 1959, General Motors started an experimental project to digitize, store and print the many design sketches being generated in the various GM design departments. When the basic concept demonstrated that it could work, they started the DAC-1 – Design Augmented by Computer – project with IBM to develop a production version. One part of the DAC project was the direct conversion of paper diagrams into 3D models, which were then converted into APT commands and cut on milling machines. In November 1963 a design for the lid of a trunk moved from 2D paper sketch to 3D clay prototype for the first time. With the exception of the initial sketch, the design-to-production loop had been closed. Meanwhile, MIT's offsite Lincoln Labs was building computers to test new transistorized designs. The ultimate goal was essentially a transistorized Whirlwind known as TX-2, but in order to test various circuit designs a smaller version known as TX-0 was built first. When construction of TX-2 started, time in TX-0 freed up and this led to a number of experiments involving interactive input and use of the machine's CRT display for graphics. Further development of these concepts led to Ivan Sutherland's ground breaking Sketchpad program on the TX-2. Sutherland moved to the University of Utah after his Sketchpad work, but it inspired other MIT graduates to attempt the first true CAD system. It was Electronic Drafting Machine (EDM), sold to Control Data and known as "Digigraphics", which Lockheed used to build production parts for the C-5 Galaxy, the first example of an end-to-end CAD/CNC production system. By 1970 there were a wide variety of CAD firms including Intergraph, Applicon, Computer vision, Auto-trol Technology, UGS Corp. and others, as well as large vendors like CDC and IBM.

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Proliferation of CNC The price of computer cycles fell drastically during the 1960s with the widespread introduction of useful minicomputers. Eventually it became less expensive to handle the motor control and feedback with a computer program than it was with dedicated servo systems. Small computers were dedicated to a single mill, placing the entire process in a small box. PDP-8's and Data General Nova computers were common in these roles. The introduction of the microprocessor in the 1970s further reduced the cost of implementation, and today almost all CNC machines use some form of microprocessor to handle all operations. The introduction of lower-cost CNC machines radically changed the manufacturing industry. Curves are as easy to cut as straight lines, complex 3-D structures are relatively easy to produce, and the number of machining steps that required human action have been dramatically reduced. With the increased automation of manufacturing processes with CNC machining, considerable improvements in consistency and quality have been achieved with no strain on the operator. CNC automation reduced the frequency of errors and provided CNC operators with time to perform additional tasks. CNC automation also allows for more flexibility in the way parts are held in the manufacturing process and the time required changing the machine to produce different components. During the early 1970s the Western economies were mired in slow economic growth and rising employment costs, and NC machines started to become more attractive. The major U.S. vendors were slow to respond to the demand for machines suitable for lower-cost NC systems, and into this void stepped the Germans. In 1979, sales of German machines surpassed the U.S. designs for the first time. This cycle quickly repeated itself, and by 1980 Japan had taken a leadership position, U.S. sales dropping all the time. Once sitting in the #1 position in terms of sales on a top-ten chart consisting entirely of U.S. companies in 1971, by 1987 Cincinnati Milacron was in 8th place on a chart heavily dominated by Japanese firms. Many researchers have commented that the U.S. focus on high-end applications left them in an uncompetitive situation when the economic downturn in the early 1970s led to greatly increased demand for low-cost NC systems. Unlike the U.S. companies, who had focused on the highly profitable aerospace market, German and Japanese manufacturers targeted lower-profit segments from the start and were able to enter the low-cost markets much more easily. Additionally, large Japanese companies established their own subsidiaries or strengthened their machine divisions to produce the machines they needed. This was seen as a national effort and largely encouraged by MITI, the Japanese Ministry for International Trade and Industry. In the early years of the development, MITI provided focused resources for the transfer of technological know-how.

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National efforts in the US were focused on integrated manufacturing from the historical perspective the defence sector maintained. This evolved in the later 1980`s, as the so-called machine tool crisis was recognized, into a number of programs that sought to broaden transfer of know how to domestic tool makers. The Air Force sponsored Next Generation Controller Program 1989 as an example. This process continued through the 1990`s to the present day from DARPA incubators and myriad research grants. As computing and networking evolved, so did direct numerical control (DNC). Its long-term coexistence with less networked variants of NC and CNC is explained by the fact that individual firms tend to stick with whatever is profitable, and their time and money for trying out alternatives is limited. This explains why machine tool models and tape storage media persist in grandfathered fashion even as the state of the art advances.

DIY, hobby, and personal CNC

Recent developments in small scale CNC have been enabled, in large part, by the Enhanced Machine Controller project in 1989 from the National Institute of Standards and Technology (NIST), an agency of the US Government's Department of Commerce. EMC [Linux CNC] is a public domain program operating under the Linux operating system and working on PC based hardware. After the NIST project ended, development continued, leading to Linux CNC which is licensed under the GNU General Public License and Lesser GNU General Public License (GPL and LGPL). Derivations of the original EMC software have also led to several proprietary low cost PC based programs notably TurboCNC, and Mach3, as well as embedded systems based on proprietary hardware. The availability of these PC based control programs has led to the development of DIY CNC, allowing hobbyists to build their own using open source hardware designs. The same basic architecture has allowed manufacturers, such as Sherline and Taig, to produce turnkey lightweight desktop milling machines for hobbyists. The easy availability of PC based software and support information of Mach3, written by Art Fenerty, lets anyone with some time and technical expertise make complex parts for home and prototype use. Fenerty is considered a principal founder of Windows-based PC CNC machining. Eventually, the homebrew architecture was fully commercialized and used to create larger machinery suitable for commercial and industrial applications. This class of equipment has been

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referred to as Personal CNC. Parallel to the evolution of personal computers, Personal CNC has its roots in EMC and PC based control, but has evolved to the point where it can replace larger conventional equipment in many instances. As with the Personal Computer, Personal CNC is characterized by equipment whose size, capabilities, and original sales price make it useful for individuals, and which is intended to be operated directly by an end user, often without professional training in CNC technology.

HISTORY OF MILLING MACHINE Milling is the machining process of using rotary cutters to remove material from a work piece by advancing (or feeding) the cutter into the work piece at a certain direction. The cutter may also be held at an angle relative to the axis of the tool. Milling covers a wide variety of different operations and machines, on scales from small individual parts to large, heavy-duty gang milling operations. It is one of the most commonly used processes for machining custom parts to precise tolerances. Milling can be done with a wide range of machine tools. The original class of machine tools for milling was the milling machine (often called a mill). After the advent of computer numerical control (CNC), milling machines evolved into machining centres: milling machines augmented by automatic tool changers, tool magazines or carousels, CNC capability, coolant systems, and enclosures. Milling centres are generally classified as vertical machining centres (VMCs) or horizontal machining centres (HMCs). The integration of milling into turning environments, and vice versa, begun with live tooling for lathes and the occasional use of mills for turning operations. This led to a new class of machine tools, multitasking machines (MTMs), which are purpose-built to facilitate milling and turning within the same work envelope. Milling evolved from rotary filing, so there is a continuum of development between the earliest milling cutters known, such as that of Jacques de Vaucanson from about the 1760s or 1770s, through the cutters of the milling pioneers of the 1810s through 1850s (Whitney, North, Johnson, Nasmyth, and others),[6] to the cutters developed by Joseph R. Brown of Brown & Sharpe in the 1860s, which were regarded as a break from the past[7][8] for their large step forward in tooth coarseness and for the geometry that could take successive sharpening without losing the clearance (rake, side rake, and so on). De Vries (1910) reported, "This revolution in the science of milling cutters took place in the States about the year 1870, and became generally known in Europe during the Exhibition in Vienna in 1873. However strange it may seem now

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that this type of cutter has been universally adopted and its undeniable superiority to the old European type is no longer doubted, it was regarded very distrustfully and European experts were very reserved in expressing their judgment. Even we ourselves can remember that after the coarse pitched cutter had been introduced, certain very clever and otherwise shrewd experts and engineers regarded the new cutting tool with many a shake of the head. However, the Worlds Exhibition at Philadelphia in 1876, exhibited to European experts a universal and many-sided application of the coarse pitched milling cutter which exceeded even the most sanguine expectations, the most far-seeing engineers were then convinced of the immense advantages which the application of the new type opened up for the metalworking industry, and from that time onwards the American type advanced, slowly at first, but later on with rapid strides". Woodbury provides citations of patents for various advances in milling cutter design, including irregular spacing of teeth (1867), forms of inserted teeth (1872), spiral groove for breaking up the cut (1881), and others. He also provides a citation on how the introduction of vertical mills brought about wider use of the end mill and fly cutter types. Scientific study by Holz and De Leeuw of the Cincinnati Milling Machine Company made the teeth even coarser and did for milling cutters what F.W. Taylor had done for single-point cutters with his famous scientific cutting studies.

Process Milling is a cutting process that uses a milling cutter to remove material from the surface of a work piece. The milling cutter is a rotary cutting tool, often with multiple cutting points. As opposed to drilling, where the tool is advanced along its rotation axis, the cutter in milling is usually moved perpendicular to its axis so that cutting occurs on the circumference of the cutter. As the milling cutter enters the work piece, the cutting edges (flutes or teeth) of the tool repeatedly cut into and exit from the material, shaving off chips (swarf) from the work piece with each pass. The cutting action is shear deformation; material is pushed off the work piece in tiny clumps that hang together to a greater or lesser extent (depending on the material) to form chips. This makes metal cutting somewhat different (in its mechanics) from slicing softer materials with a blade. The milling process removes material by performing many separate, small cuts. This is accomplished by using a cutter with many teeth, spinning the cutter at high speed, or advancing the material through the cutter slowly; most often it is some combination of these three

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approaches. The speeds and feeds used are varied to suit a combination of variables. The speed at which the piece advances through the cutter is called feed rate, or just feed; it is most often measured in length of material per full revolution of the cutter.

There are two major classes of milling process:

1. In face milling, the cutting action occurs primarily at the end corners of the milling cutter. Face milling is used to cut flat surfaces (faces) into the work piece, or to cut flatbottomed cavities.

2. In peripheral milling, the cutting action occurs primarily along the circumference of the cutter, so that the cross section of the milled surface ends up receiving the shape of the cutter. In this case the blades of the cutter can be seen as scooping out material from the work piece. Peripheral milling is well suited to the cutting of deep slots, threads, and gear teeth.

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TYPES OF MILL CUTTER NO 1

TYPE OF MILLS End Mill

DESCRIPTION End mills are tools which have cutting teeth at one end, as well as on the sides. The words end mill is generally used to refer to flat bottomed cutters, but also include rounded cutters and radiuses cutters. They are usually made from high speed steel or cemented carbide, and have one or more flutes. They are the most common tool used in a vertical mill. Roughing end mills quickly remove large amounts of material. This kind of end mill utilizes a wavy tooth form cut on the periphery. These wavy teeth form many successive cutting edges producing many small chips, resulting in a relatively rough surface finish.

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Roughing end mill

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Ball cutter

Ball nose cutters or ball end mills are similar to slot drills, but the end of the cutters are hemispherical. They are ideal for machining 3dimensional contoured shapes in machining centres, for example in moulds and dies.

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Slab mill

5

Side-andface cutter

Slab mills are used either by themselves or in gang milling operations on manual horizontal or universal milling machines to machine large broad surfaces quickly. They have been superseded by the use of cemented carbide-tipped face mills which are then used in vertical mills or machining centres. The side-and-face cutter is designed with cutting teeth on its side as well as its circumference. They are made in varying diameters and widths depending on the application. The teeth on the side allow the cutter to make unbalanced cuts without deflecting the cutter as would happen with a slitting saw or slot cutter.

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Involute gear cutter

There are 8 cutters that will cut gears from 12 teeth through to a rack.

EXAMPLE

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Hob

These cutters are a type of form tool and are used in hobbing machines to generate gears. A cross section of the cutter's tooth will generate the required shape on the work piece, once set to the appropriate conditions. A hobbing machine is a specialised milling machine.

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Thread mill

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Face mill

Whereas a hob engages the work much as a mating gear would a thread milling cutter operates much like an end mill, traveling around the work in a helical interpolation. A face mill is a cutter designed for facing as opposed to creating a pocket.

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Fly cutter

A fly cutter is composed of a body into which one or two tool bits are inserted. Fly cutters are analogous to face mills in that their purpose is face milling and their individual cutters are replaceable. Face mills are more ideal in various respects but tend to be expensive, whereas fly cutters are very inexpensive.

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Woodruff cutter

Woodruff cutters are used to cut the keyway for a woodruff key.

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Hollow mill

Hollow milling cutters, more often called simply hollow mills, are essentially "inside-out end mills". They are shaped like a piece of pipe with their cutting edges on the inside surface. They are used on turret lathes and screw machines as an alternative to turning with a box tool, or on milling machines or drill presses to finish a cylindrical boss (such as a trunnion).

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Dovetail cutter

A dovetail cutter is an end mill whose form leaves behind a dovetail slot, such as often forms the ways of a machine tool.

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Shell mill

1. Modular principle - A shell mill is any of various milling cutters whose construction takes a modular form, with the shank (arbor) made separately from the body of the cutter, which is called a "shell" and attaches to the shank/arbor via any of several standardized joining methods. 2. Mounting methods - The most common type of joint between shell and arbor involves a fairly large cylindrical feature at centre (to locate the shell concentric to the arbor) and two driving lugs or tangs that drive the shell with a positive engagement (like a dog clutch). Within the central cylindrical area, one or several socket head cap screws fasten the shell to the arbor.

Reka bentuk

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COST

ENVIRONMENT

SAFETY

PRODUCT DESIGN

QUALITY

FUNCTION

ERGONOMICS

A.

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B.

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C.

Inovasi plotter (A,B,C)

Aspek yang perlu ada:

1. Safety  Emergency stop button

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2. Cost  Low cost 3. Quality  Durable 4. Ergonomics  User friendly 5. Environments  Less space consumption 6. Program  Mach 3

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Pengujian

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Proses otak & software 1) Breakout board

Breakout board (BOB) is an electronic card that functions to connect data signals from a computer with both input and output peripherals.Breakout board is the main component use to assemble cnc machines, connecting data signals from computer to driver or relay, and connecting external input signals from computer reading. Breakout board uses parallel PORT DB25 computer, can work using MACH3 software or other similar software that works with parallel PORT DB25. Excess Breakout board is more resistant to external interface noise. The weakness of the breakout board is a bit of a feature, and there is no analog output feature. It is suitable for cnc plasma machine.

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2) MACH3 Basic MACH functions:  Allows direct import of DXF, BMP, JPG, and HPGL files through Lazycam Visual G code display.  Generates G code via LazyCam or Wizards.  Fully customizable interface.  Customizable M-codes and Macros using VBscript.

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3)SCAN2CAD

Scan2CAD is raster and vector conversion and editing CAD (Computer-aided design) software. The software is developed in the UK by Avia Systems. Scan2CAD's first version was released in 1993. The publishing company was Softcover International. This company continued to publish the software until 2010 when Avia Systems acquired the software.

29 The development team has continued to be the same throughout the full lifetime of the software. Scan2CAD is now used across the world by a very wide variety of users ranging from government and large industrial organisations to smaller individual firms. It has been translated to 4 localised language versions including Polish, Italian, French and Japanese. A free trial of the Scan2CAD software is currently bundled with the HP T2300 scanner.

Bab 3- Methodologi Kajian Pengenalan

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Methodology is an engineering aspects that needs to be taken into account in producing a product. Methodology is defined as the mean of selection and analysis. In addition, methodology is product that made perfectly and brilliantly completed. Methodology is also a method and technique of designing, collecting and analysing data in order to produce evidence that can support a study and why a particular study and technique is used. Methodology includes a collection of coherent philosophy theorem, concept or idea as it relates to a field or field of inquiry. It refers to more than a simple set of methods. Methodology also refers to the rational and philosophical assumptions that the study as a bottom is compared to scientific methods. This is why scientific literature often contains a section on researchers. Every step of the project is a process to make sure the project to flow as planned. Every step must be followed by one and needs to be done carefully. If some mistakes happen it can make the project may not be operative or does not seem neat and perfect.

Flow Chart

STATE THE PROBLEM OF THE EXISTING PRODUCT

RESEARCH

BRAIN STORMING

31

DESIGN PROCESS BEGIN

NO PROJECT TESTING

YES

THE END

Proses Dilaksanakan (mesin,kimpal,sambungan,lukisan,inventor) TIG welding machine

RETRY

32

MIG welding machine

Pengujian Standard

33

Bab 4-Rekabentuk Kajian

For the design of Portable Plotter Machine, researcher use concept of Cartesian Robot as movement concept, there was three axis that being use for including x, y and z. The concept of machine use robot which is use specific program and need accuracy for the design. There was a lot of aspect that need to be considered by researcher start with body, electronic part and also mechanical part.

Figure 4.1 Draft Design

Figure 4.2 Base Design and Concept

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Inventor

35

Harga bahan

36

No. Item Name

Quantity Cost per

unit Total (RM)

(RM) 1.

Bearing

6

12.00

72.00

2.

Arduino uno

1

35.00

35.00

3.

Wooden Plate

1

55.00

55.00

4.

Stepper Motor

3

40.00

120.00

5.

Screw One Set

1

15.90

15.90

6.

Junction 1 set

1

10.00

10.00

7.

Plastic

1

30.00

30.00

Overall

336.00

Breakout Board

Breakout board (BOB) is an electronic card that functions to connect data signals from a computer with both input and output peripherals.Breakout board is the main component use to assemble cnc machines, connecting data signals from computer to driver or relay, and connecting external input signals from computer reading.

Breakout board uses parallel PORT DB25 computer, can work using MACH3 software or other similar software that works with parallel PORT DB25. Excess Breakout board is more resistant to external interface noise. The weakness of the breakout board is a bit of a feature, and there is no analog output feature. It is suitable for cnc plasma machine.

37

Bab 5-Dapatan Kajian

38

Rekabentuk

For the design of Portable Plotter Machine, researcher use concept of Cartesian Robot as movement concept, there was three axis that being use for including x, y and z. The concept of machine use robot which is use specific program and need accuracy for the design. There was a lot of aspect that need to be considered by researcher start with body, electronic part and also mechanical part.

Figure 5.1 Draft Design

Figure 5.2 Base Design and Concept

Inovasi

39

Proses

Pengujian Data

40

Bab 6-Perbincangan

41

Rekabentuk For the design of Portable Plotter Machine, researcher use concept of Cartesian Robot as movement concept, there was three axis that being use for including x, y and z. The concept of machine use robot which is use specific program and need accuracy for the design. There was a lot of aspect that need to be considered by researcher start with body, electronic part and also mechanical part.

Figure 6.1 Draft Design

Figure 6.2 Base Design and Concept

Inovasi

42

Proses

43

Pengujian Data

44

Bab 7-Kesimpulan

45

Cadangan

46

Bab 8-RujuKan

Bab 9-Lampiran INTERNET 1. History of numerical control https://en.wikipedia.org/wiki/History_of_numerical_control 2. Numerical control https://en.wikipedia.org/wiki/Numerical_control 3. Milling (machining) https://en.wikipedia.org/wiki/Milling_(machining) 4.