April 2017

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April 21, 2017 / Leave a Comment / CNC / admin

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Do you like to build things? Are you ever frustrated at having to compromise your designs to fit whatever parts happen to be available? Would you like to fabricate your own parts? Build Your Own CNC Machine is the book to get you started. CNC expert Patrick Hood-Daniel and best-selling author James Kelly team up to show you how to construct your very own CNC machine. Then they go on to show you how to use it, how to document your designs in Computer-Aided Design programs, and how to output your designs as specifications and tool paths that feed into the CNC machine, controlling it as it builds whatever parts your imagination can dream up.
Don’t be intimidated by abbreviations like CNC and terms like Computer-Aided Design. Patrick and James have chosen a CNC-machine design that is simple to fabricate. You need only basic woodworking skills and a budget of perhaps $500 to $1,000 to spend on the wood, a router, and various other parts that you’ll need. With some patience and some follow-through, you’ll soon be up and running with a really fun machine that’ll unleash your creativity and turn your imagination into physical reality.
The authors go on to show you how to test your machine, including configuring the software.
Provides links for learning how to design and mill whatever you can dream up
The perfect parent/child project that is also suitable for scouting groups, clubs, school shop classes, and other organizations that benefit from projects that foster skills development and teamwork
No unusual tools needed beyond a circular saw and what you likely already have in your home toolbox
Teaches you to design and mill your very own wooden and aluminum parts, toys, gadgets—whatever you can dream up
What you’ll learn
Build your very own CNC machine
Learn about linear movement and motion transmission
Who is this book for?
Build Your Own CNC Machine is the perfect book for hobbyists who like to build and create using wood and metal. It’s especially for those who have ever been foiled by lack of specific parts to help realize their creative designs. Build Your Own CNC Machine is also an excellent choice for organizations such as scouting and church groups, school shop classes, and so forth, as it provides an educational project of modest cost that all can work on together.
Contents
■About the Authors …………………………………………………………………………………………………… x
■About the Technical Reviewers ……………………………………………………………………………….. xi
■Acknowledgments ………………………………………………………………………………………………… xii
■Introduction ………………………………………………………………………………………………………….. xiii
■Chapter 1: Your CNC Machine …………………………………………………………………………………. 1
What is CNC? ……………………………………………………………………………………………………………… 1
Industrial Uses ……………………………………………………………………………………………………. 2
Personal Uses …………………………………………………………………………………………………….. 2
Your DIY CNC Machine …………………………………………………………………………………………………. 3
What’s Next? ………………………………………………………………………………………………………………. 4
■Chapter 2: Hardware and Tools ………………………………………………………………………………. 5
The Tools …………………………………………………………………………………………………………………… 5
The Electronics Vendors ……………………………………………………………………………………………… 12
What’s Next? …………………………………………………………………………………………………………….. 12
■Chapter 3: Tips and Advice …………………………………………………………………………………… 13
Cut Once ………………………………………………………………………………………………………………….. 13
Protect Yourself …………………………………………………………………………………………………………. 14
Protect Your Lungs …………………………………………………………………………………………………….. 15
Label Parts ……………………………………………………………………………………………………………….. 16
MDF Sheets and Sizes ………………………………………………………………………………………………… 17
Limit Your Cuts ………………………………………………………………………………………………………….. 18
Time Your Cuts ………………………………………………………………………………………………………….. 20
Encouragement …………………………………………………………………………………………………………. 20
What’s Next? …………………………………………………………………………………………………………….. 21
■Chapter 4: Movement Using Rails ………………………………………………………………………… 23
Bearing-Rail Assembly ……………………………………………………………………………………………….. 23
Riding the Rail …………………………………………………………………………………………………………… 32
Tips and Advice …………………………………………………………………………………………………………. 33
What’s Next? …………………………………………………………………………………………………………….. 33
■Chapter 5: Joining Methods ………………………………………………………………………………….. 35
Two Pieces of MDF ……………………………………………………………………………………………………. 35
Method 1: Cross Dowels ……………………………………………………………………………………………… 38
Method 2: Bolt, Washer, and Nut ………………………………………………………………………………….. 43
Which Method Is Best? ……………………………………………………………………………………………….. 44
Building a Jig to Drill ………………………………………………………………………………………………….. 45
What’s Next? …………………………………………………………………………………………………………….. 47
■Chapter 6: The Electronics ……………………………………………………………………………………. 49
The Required Components ………………………………………………………………………………………….. 49
Preparing the Stepper Motor Wires ……………………………………………………………………………….. 53
Preparing the Power Supply ………………………………………………………………………………………… 56
Preparing the Breakout Board………………………………………………………………………………………. 59
Providing Power to the Stepper Motor Drivers …………………………………………………………………. 62
Wiring Motor Drivers to the Breakout Board ……………………………………………………………………. 64
Connecting Power to Motor Drivers ………………………………………………………………………………. 65
Connecting Stepper Motors to Motor Drivers ………………………………………………………………….. 67
Wiring the Cooling Fan ……………………………………………………………………………………………….. 69
Testing the Electronics ……………………………………………………………………………………………….. 70
What’s Next? …………………………………………………………………………………………………………….. 71
■Chapter 7: X-Axis, Part 1 ………………………………………………………………………………………. 73
The X-Axis MDF Parts …………………………………………………………………………………………………. 73
The X-Axis Table ……………………………………………………………………………………………………….. 74
Cutting Rails for Tabletop Sides ……………………………………………………………………………………. 79
Summary of Work ……………………………………………………………………………………………………… 80
What’s Next? …………………………………………………………………………………………………………….. 80
■Chapter 8: X-Axis, Part 2 ………………………………………………………………………………………. 81
Drilling the Table ……………………………………………………………………………………………………….. 81
Drilling Holes for Legs ………………………………………………………………………………………………… 85
Cutting the Table Ends ……………………………………………………………………………………………….. 86
Summary of Work ……………………………………………………………………………………………………… 90
Hardware Required ……………………………………………………………………………………………………. 90
What’s Next? …………………………………………………………………………………………………………….. 90
■Chapter 9: X-Axis, Part 3 ………………………………………………………………………………………. 91
Drilling the Table Ends (Legs) ………………………………………………………………………………………. 91
Drilling and Mounting the Rail ……………………………………………………………………………………… 95
Attaching the Table Legs …………………………………………………………………………………………….. 96
Cutting the X-Axis Lead Screw …………………………………………………………………………………….. 97
Summary of Work ……………………………………………………………………………………………………… 98
Hardware Required ……………………………………………………………………………………………………. 98
What’s Next? …………………………………………………………………………………………………………….. 98
■Chapter 10: Y-Axis, Part 1 …………………………………………………………………………………….. 99
The Y-Axis MDF Parts …………………………………………………………………………………………………. 99
Parts Q and R: The Y-Axis Gantry Sides ……………………………………………………………….. 100
Building BRAs for Gantry Sides…………………………………………………………………………… 105
Summary of Work ……………………………………………………………………………………………………. 108
Hardware Required ………………………………………………………………………………………………….. 108
What’s Next? …………………………………………………………………………………………………………… 108
■Chapter 11: Y-Axis, Part 2 …………………………………………………………………………………… 109
The Y-Axis MDF Parts ……………………………………………………………………………………………….. 109
Attaching BRAs and Gantry Sides ……………………………………………………………………………….. 110
Part P: The Y-Axis Gantry Bottom Support ……………………………………………………………………. 114
Summary of Work ……………………………………………………………………………………………………. 119
Hardware Required ………………………………………………………………………………………………….. 120
What’s Next? …………………………………………………………………………………………………………… 120
■Chapter 12: Y-Axis, Part 3 …………………………………………………………………………………… 121
The Y-Axis MDF Parts ……………………………………………………………………………………………….. 121
The Rail Support ………………………………………………………………………………………………………. 122
Finishing the Y-Axis Frame ………………………………………………………………………………………… 128
Tips on Final Frame Assembly ……………………………………………………………………………………. 132
Summary of Work ……………………………………………………………………………………………………. 132
Hardware Required ………………………………………………………………………………………………….. 132
What’s Next? …………………………………………………………………………………………………………… 133
■Chapter 13: Preparing for the Z-Axis ………………………………………………………………….. 135
The Y-Axis BRA Supports ………………………………………………………………………………………….. 135
Cutting and Drilling Parts C and D ………………………………………………………………………………. 136
Measuring for the Z-Axis …………………………………………………………………………………………… 144
Summary of Work ……………………………………………………………………………………………………. 146
Hardware Required ………………………………………………………………………………………………….. 147
What’s Next? …………………………………………………………………………………………………………… 147
■Chapter 14: Z-Axis, Part 1 …………………………………………………………………………………… 149
The Z-Axis MDF Parts ……………………………………………………………………………………………….. 149
Part F: The Z-Axis Rail Support …………………………………………………………………………………… 150
Parts W and X: The Z-Axis Bearing Supports ………………………………………………………………… 154
Z-Axis Bearing-Rail Assemblies ………………………………………………………………………………….. 155
Summary of Work ……………………………………………………………………………………………………. 157
Hardware Required ………………………………………………………………………………………………….. 157
What’s Next? …………………………………………………………………………………………………………… 157
■Chapter 15: Z-Axis, Part 2 …………………………………………………………………………………… 159
Preparing to Drill ……………………………………………………………………………………………………… 159
Drilling Part F: The Z-Axis Rail Support ………………………………………………………………………… 159
Drilling Parts W and X: The Z-Axis Bearing Supports ………………………………………………………. 161
Mounting the Z-Axis Bearing-Rail Assemblies ……………………………………………………………….. 164
Summary of Work ……………………………………………………………………………………………………. 166
Hardware Required ………………………………………………………………………………………………….. 166
What’s Next? …………………………………………………………………………………………………………… 166
■Chapter 16: Z-Axis, Part 3 …………………………………………………………………………………… 167
Cutting the Z-Axis Rail Support Rails …………………………………………………………………………… 167
Cutting and Drilling Parts M and N ……………………………………………………………………… 169
Cutting and Drilling Part V …………………………………………………………………………………. 173
Assembling the Z-Axis ………………………………………………………………………………………………. 174
Attaching the Z-Axis to the Machine ……………………………………………………………………………. 176
Summary of Work ……………………………………………………………………………………………………. 181
Hardware Required ………………………………………………………………………………………………….. 181
What’s Next? …………………………………………………………………………………………………………… 181
■Chapter 17: Mounting the Electronics …………………………………………………………………. 183
Cutting and Drilling the Motor Mounts …………………………………………………………………………. 183
Mounting Your Router ……………………………………………………………………………………………….. 191
Summary of Work ……………………………………………………………………………………………………. 194
Hardware Required ………………………………………………………………………………………………….. 195
What’s Next? …………………………………………………………………………………………………………… 195
■Chapter 18: Software and Testing ……………………………………………………………………….. 197
CAD, CAM, and Control Software ………………………………………………………………………………… 197
The Mach3 Control Software ……………………………………………………………………………………… 197
Downloading and Installing Mach3 ……………………………………………………………………………… 198
Configuring Mach3 …………………………………………………………………………………………………… 200
Ports and Pins …………………………………………………………………………………………………. 200
Motor Outputs …………………………………………………………………………………………………. 201
Input Signals …………………………………………………………………………………………………… 201
Motor Tuning and Setup ……………………………………………………………………………………. 202
Configuring the Default Motor Units ……………………………………………………………………. 203
Testing Your Machine ……………………………………………………………………………………………….. 203
Testing the Router ……………………………………………………………………………………………………. 206
School Starts …………………………………………………………………………………………………………… 207
What’s Next? …………………………………………………………………………………………………………… 208
■Chapter 19: Where to Go from Here …………………………………………………………………….. 209
Getting Familiar with CAD ………………………………………………………………………………………….. 209
Getting Familiar with CAM …………………………………………………………………………………………. 210
Installing an Emergency Stop …………………………………………………………………………………….. 210
Adding Limit Switches ………………………………………………………………………………………………. 213
Adding a Solid State Relay …………………………………………………………………………………………. 214
Protecting and Painting Your Machine …………………………………………………………………………. 215
What’s Next? …………………………………………………………………………………………………………… 215
■Index ………………………………………………………………………………………………………………….. 217
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FeatureCAM allows you to:
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DriveWorks Pro is an add-on for SolidWorks, designed to automate the process of project development and repetitive tasks. Provides rapid and consistent development of 3D models and 2D drawings, commercial quotas, BOMs, Cut Lists, DXF’s (open file format for the exchange of two-dimensional graphical information between CAD applications, was created by Autodesk for the AutoCAD system. It is supported by virtually all CAD systems on the platform PC.)
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DriveWorks Solo is an add-on for SolidWorks, designed to automate the process of project development and repetitive tasks. Provides rapid and consistent development of 3D models and 2D drawings, commercial quotas, BOMs, Cut Lists, DXF’s (open file format for the exchange of two-dimensional graphical information between CAD applications, was created by Autodesk for the AutoCAD system. It is supported by virtually all CAD systems on the platform PC.)
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PolyWorks (PW) is a multifunctional software company manufactured by InnovMetricSoftwareInc., Used to process laser scanning data: reverse engineering, product geometry control, architecture tasks, deformation monitoring of the earth’s surface and many others. The PolyWorks software package allows you to efficiently and quickly work with very large amounts of data. PolyWorks consists of several modules and has a wide range of tools that simplify and accelerate the work with data. It is important to note that the complex allows you to work with data obtained from three-dimensional scanners of all known brands.
IMAlign
• This module is designed for primary data processing.
• Initially, data is imported using a terrestrial 3D scanner or data already processed in other programs. Already at this stage, there are some processing possibilities: the data is imported with the specified accuracy (the step of sampling points is set); Data can be filtered by distance.
• Primary processing of point clouds: scaling of point clouds; Filtering on the subject of coincident points, that is, ordering (the points diverging to distances less than the specified ones are deleted). In the module, you bind to the external coordinate system and link the scans.
• The program allows you to select the stitching method, which can be divided into: visual stitching methods; On reference objects. And that is not unimportant: the program produces statistics and histograms of association errors, primary polygonal models are created.
• Data can be exported in many formats (AC, BRE, PIF, PTX, SURF) and as polygonal models in DXF, IGES.
IMMerge
• Designed to create a triangulation model, the module allows you to manually determine the parameters responsible for the quality and accuracy of the model being created.
IMEdit
• The module is designed to work with TIN-surfaces created in PW or imported from other programs.
• The module contains functions for smoothing, filling “holes”, retryangulation (individual areas can be re-arranged with less accuracy), various mechanisms for creating curves and tools for editing them.
• This module implements the functions of creating and editing NURBS surfaces – surfaces that are created by curves, and the module provides many ways to create these curves: manually – certain curves are drawn at the specified points, the curves are constructed by intersections with the plane model, by sections , A grid of curves is automatically compiled from the model with a specified accuracy (the step and the maximum distance to which they are spaced from the model).
IMInspect
Includes tools that allow:
• to enter into the cloud points of geometric primitives (circle, cone, cylinder, plane, point, polyline, sphere and vector);
• construction of polygonal surfaces;
• combining data and reference objects into a single and unique coordinate system;
• profiling, creating arbitrary and specified sections;
• make detailed comparisons, statistics and reports within or between data, reference objects, and primitives;
• All types of measurements, control of position and condition of complex structures (measurement of geometric dimensions, both linear and angular, areas, volumes);
• export data and reference objects to many formats.
IMCompress
• Reduction, mainly, of colored polygonal 3D models. An auxiliary module that allows you to reduce the weight of the model by reducing the number of its constituent elements (triangles or patches).
IMTexture
• The module allows you to combine the model and its texture map, that is, get a model with textures that displays not only the geometric, but also the physical properties of the model. The texture map should be obtained from the scanner, that is, in the obtained data from the scanner, in addition to coordinates, there should be information about the intensity. Two types of data are combined, as a result, the model has the form closest to reality.
IMView
• Module for viewing data.
• Models created in the program are saved in the internal format and can be viewed in the free module provided. The software product PolyWorks is intended for a certain range of tasks, the solution of which in other software products is not possible.
• This range of tasks covers many aspects. For example: Monitoring of deformations of the earth’s surface, landslide processes and subsidence of soil under the influence of technogenic factors. By superimposing models created at different times, one can obtain the magnitude and direction of the displacements. And to characterize the data for these offsets will not be individual control points.
• Since continuous scanning is performed during scanning, the necessary information can be obtained practically at any point of the surface. The data obtained are presented in the form of a colored three-dimensional model with a color distribution depending on the magnitude of the deformations.
• By simply clicking the mouse at any point of this model, the magnitude and direction of the deformation, as well as the coordinates of the given point in different observation cycles, are displayed on the screen. Then, the distribution diagrams of these quantities are generated, which can be transformed into various charts, diagrams and histograms in MS Excel format.
• The three-dimensional model of the earth’s surface allows solving a number of problems, ranging from the calculation of the volume of blasting blocks in open quarries being developed and ending with the usual topographic plan and materials for land management documentation.
• With the tools of the PolyWorks software product in the automatic mode, in this case it is also possible to solve the following tasks:
Analysis of surfaces (magnitude and direction of deformation). Surface analysis – cuts (they can be performed in different directions: perpendicular to the board and in the horizontal planes: in the first case this is one of the main parameters for assessing the quality of the explosion and the location of the ore, in the other we get a career planplanet).
• Construction of isolines of the camber surface. Evaluation of the collapse and exploded volume (the estimation of the disintegration according to these models can be performed as follows: the collapse is divided into calculation blocks (for example, 3 × 3 m) and the volume of each such block is estimated, these calculations are taken from the calculated plane at a given mark). Tasks of industrial enterprises related to the measurement of inaccessible and complex objects, the construction of three-dimensional models of objects and the preparation of materials for use in automatic design systems and enterprise management systems. Monitoring the condition of buildings and structures, in particular, monitoring deformations.
• By superimposing models created at different times, you can obtain the magnitude and direction of the displacements at any point in the structure. It is possible to overlay the current model with a “reference” model, the role of which can be played by the project model. In this case, we will have deviations from the “ideal” parameters. An example of such a deformation is the deflection of the hipped roof.
• Deformational monitoring is carried out both for the building as a whole and for individual structural elements, including those that are inaccessible.
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