3-AXIS CNC MARBLE CUTTING AND CARVING

MACHINE

Group Members
HADI ZAMAN 170582
MU UZAIR HUSSAIN 170603
MAHNOOR AMJAD 170627

BE MECHATRONICS (2017-2021)

Project Supervisor
ENGR. ZAHID HUSSAIN
Assistant Professor

Co supervisor
ENGR. SHABKHEZ SARWAR
Lecturer

DEPARTMENT OF MECHATRONICS ENGINEERING & BIOMEDICAL

ENGINEERING
FACULTY OF ENGINEERING
AIR UNIVERSITY, ISLAMABAD
3-AXIS CNC MARBLE CUTTING AND CARVING
MACHINE
FINAL YEAR PROJECT
(SESSION 2017-2021)

DEPARTMENT OF MECHATRONICS ENGINEERING & BIOMEDICAL

ENGINEERING
3-AXIS CNC MARBLE CUTTING AND CARVING
MACHINE

Submitted by:

HADI ZAMAN 170582

M UZAIR HUSSAIN 170603
MAHNOOR AMJAD 170627

Project Supervisor

Engr. Zahid Hussain

Assistant Professor

Chair Department

Dr. Rana Iqtidar Shakoor

 Acknowledgement

We are firstly grateful to Allah and then would like to appreciate the personal without
which this could not be possible. We thank our supervisor Engr. Zahid Hussain for his
immeasurable support and encouragement regarding this research and project. His ad-
vice and assistance were crucial for this project. We sincerely thank you for your time
and dedication.
Our appreciation for the staff of Mechatronics department, Air university and our fel-
low students, who have helped us in many ways and for making our educational road
pleasant and memorable.
We acknowledge our gratitude to our Parents and family members for the love, sacri-
fice, support and courage they put in order for this project to work. They have been the
back bone for what we are today and no words can describe their devotion, hope and
faith in achieving our goals. We would like to thank any person who has contributed to
this project hidden or in open. Their remarks and reviews were crucial for our success
in this project.

iii
 Abstract

The project is about “3-Axis CNC Marble Cutting and Carving Machine”, it offers the
ability to cut and carve complex shapes using raw marble hence adds value in marble
products. Marble structures are a part of Pakistan’s culture. Almost every house, has
marble work done in it. But we are limited to certain simple designs and skilled crafts-
men take much longer time and effort to make such designs. CNC machines are more
useful and accurate hence can favor local marble industries to grow economically by
adding value to raw marble through carving and cutting, by speeding up their produc-
tion with high quality and good designed marble. This project will help in designing and
fabrication of marble products in lesser time, it will easily produce different patterns and
shapes which would take a normal person several hours or may be days. Machine has
simple CNC Router Design, having bed size 2x2 ft, it operates on stepper motors and
based on Mach 3 controller. The CAD and CAM software used for G-code preparation
are open source software.

iv
 Table of Contents

Acknowledgements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Abstract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv

Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x

List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii

Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiv

Chapter 1: Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Computer Numerical Control (CNC) . . . . . . . . . . . . . . . . . . . 1
1.1.1 Types of CNC machines: . . . . . . . . . . . . . . . . . . . . . 1
1.1.2 Classification of CNC machines: . . . . . . . . . . . . . . . . . 2
1.1.3 Applications of CNC machines: . . . . . . . . . . . . . . . . . 2
1.1.4 Advantages of CNC machine: . . . . . . . . . . . . . . . . . . 2
1.1.5 Disadvantages of CNC machines: . . . . . . . . . . . . . . . . 3
1.2 Problem Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Motivation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4 Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.5 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.5.1 Limitations: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.6 Cost Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.7 Timeline: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.8 Organization of Report . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Chapter 2: Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1 Literature Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

v
2.2 Methodology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.3 CNC ROUTER for Marble cutting and Carving . . . . . . . . . . . . . 13
2.4 CNC Router Operation Flow . . . . . . . . . . . . . . . . . . . . . . . 13
2.5 CNC Router Block Diagram . . . . . . . . . . . . . . . . . . . . . . . 14
2.6 CAD Software: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.7 CAM software: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.8 Programming Language: . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.8.1 G code: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.8.2 M code: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.9 Motion Controller Card . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.10 Components Description . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.10.1 Stepper Motor: . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.10.2 Water pump: . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.10.3 Bed: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.10.4 Ball screw rods: . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.10.5 Linear Rails: . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.10.6 Spindle: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.10.7 Emergency Stop: . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.10.8 Auto Calibration Sensor: . . . . . . . . . . . . . . . . . . . . . 21
2.10.9 Tools and Tool Holders: . . . . . . . . . . . . . . . . . . . . . 22
2.10.10 Cutting Tools: . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.11 Product Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.12 ISO Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.13 Engineering Design Calculations . . . . . . . . . . . . . . . . . . . . . 25
2.13.1 Calculating Lead screw forces: . . . . . . . . . . . . . . . . . 25
2.13.2 Calculating force due to acceleration: . . . . . . . . . . . . . . 25
2.13.3 Calculating force due to friction: . . . . . . . . . . . . . . . . 26
2.13.4 Calculating external forces: . . . . . . . . . . . . . . . . . . . 26

vi
 2.13.5 Total Lead screw force: . . . . . . . . . . . . . . . . . . . . . 26
2.13.6 Calculating Lead screw inertia: . . . . . . . . . . . . . . . . . 26
2.13.7 Calculating friction torque : . . . . . . . . . . . . . . . . . . . 27
2.13.8 Calculating acceleration torque: . . . . . . . . . . . . . . . . . 27
2.13.9 Calculating load inertia: . . . . . . . . . . . . . . . . . . . . 28
2.13.10 Motor Torque: . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.13.11 Calculating cutting speed: . . . . . . . . . . . . . . . . . . . . 28
2.13.12 Calculating spindle speed: . . . . . . . . . . . . . . . . . . . . 29
2.13.13 Calculating feed rate: . . . . . . . . . . . . . . . . . . . . . . 29
2.13.14 Calculating drive motor torque: . . . . . . . . . . . . . . . . . 29

Chapter 3: Modeling and Simulations . . . . . . . . . . . . . . . . . . . . . . 30

3.1 CAD MODELING: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.1.1 Base: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.1.2 Bed: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.1.3 Linear Rails: . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.1.4 X-Rail Bracket: . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.1.5 Y axis Rail Bracket: . . . . . . . . . . . . . . . . . . . . . . . 32
3.1.6 Ball bearing Rods: . . . . . . . . . . . . . . . . . . . . . . . . 33
3.1.7 Bearing Rod Pad: . . . . . . . . . . . . . . . . . . . . . . . . 33
3.1.8 Base support/ Legs: . . . . . . . . . . . . . . . . . . . . . . . 34
3.1.9 X Gantry movement plate: . . . . . . . . . . . . . . . . . . . . 35
3.1.10 Y axis Support: . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.1.11 Z-axis Gantry: . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.1.12 Spindle: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.2 CAD MODEL: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.3 Stress and Strain Analysis: . . . . . . . . . . . . . . . . . . . . . . . . 38
3.4 MATLAB/SIMULINK MODELING: . . . . . . . . . . . . . . . . . . 39

vii
 3.4.1 Introduction: . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.4.2 Motion Profile: . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.5 Simulink Modeling: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.5.1 Simulation results: . . . . . . . . . . . . . . . . . . . . . . . . 45
3.6 Control and Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.7 Microstep driver DM542: . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.8 Limit switch: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.9 MACH3 Controller: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.9.1 Features of MACH3 controller: . . . . . . . . . . . . . . . . . 49
3.9.2 MACH3 Software: . . . . . . . . . . . . . . . . . . . . . . . . 50
3.10 Calibration Method: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.10.1 STEP 1: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.10.2 STEP 2: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.10.3 STEP 3: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.10.4 STEP 4: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.10.5 STEP 5: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.10.6 STEP 6: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.10.7 STEP 7: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.10.8 STEP 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.10.9 STEP 9: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.10.10 Determining steps per unit length: . . . . . . . . . . . . . . . . 56

Chapter 4: Experimental Setup . . . . . . . . . . . . . . . . . . . . . . . . . . 57

4.1 Working Area (Bed) of CNC Router . . . . . . . . . . . . . . . . . . . 57
4.2 Base and Water tub of CNC Router . . . . . . . . . . . . . . . . . . . 57
4.3 Water drainage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4.4 Motors for 3 axis CNC Router . . . . . . . . . . . . . . . . . . . . . . 58
4.5 Ball Bearing Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

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 4.6 Linear rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.7 X axis of CNC Router . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.8 Y axis of CNC Router . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.9 Z axis and Spindle of CNC Router . . . . . . . . . . . . . . . . . . . . 61
4.10 Control Panel of CNC Router . . . . . . . . . . . . . . . . . . . . . . . 61
4.11 Mechanical Setup of CNC Router . . . . . . . . . . . . . . . . . . . . 62

Chapter 5: Results and Discussion . . . . . . . . . . . . . . . . . . . . . . . . 63

5.1 Results: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.1.1 Testing on wood . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.1.2 Testing on marble without water . . . . . . . . . . . . . . . . . 64
5.1.3 Testing on marble with water . . . . . . . . . . . . . . . . . . 64
5.1.4 Accuracy of CNC Router . . . . . . . . . . . . . . . . . . . . . 65
5.2 Discussion: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Chapter 6: Conclusion and Recommendations . . . . . . . . . . . . . . . . . 67

6.1 Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
6.2 Recommendations for future work . . . . . . . . . . . . . . . . . . . . 67

References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

ix
 List of Figures

Figure 2.1 Basic image of CNC Router . . . . . . . . . . . . . . . . . . . . 8

Figure 2.2 Different controller cards for CNC Routers . . . . . . . . . . . . 17
Figure 2.3 Stepper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Figure 2.4 Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Figure 2.5 Bed of CNC machine . . . . . . . . . . . . . . . . . . . . . . . 19
Figure 2.6 Ball screw Rod . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Figure 2.7 Linear Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Figure 2.8 Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Figure 2.9 Emergency stop Button . . . . . . . . . . . . . . . . . . . . . . 21
Figure 2.10 Auto calibration Sensor . . . . . . . . . . . . . . . . . . . . . . 21
Figure 2.11 HSK tool holder . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Figure 2.12 Bits for cutting and carving marble . . . . . . . . . . . . . . . . 22
Figure 2.13 List of tools for cutting and carving . . . . . . . . . . . . . . . . 23
Figure 3.1 CAD design of CNC Base . . . . . . . . . . . . . . . . . . . . 30
Figure 3.2 Side view of bed . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Figure 3.3 Front view and dimension of rail . . . . . . . . . . . . . . . . . 31
Figure 3.4 Front view of X Rail . . . . . . . . . . . . . . . . . . . . . . . . 32
Figure 3.5 Drawing and dimension of Y bracket . . . . . . . . . . . . . . . 32
Figure 3.6 Ball bearing rod side view . . . . . . . . . . . . . . . . . . . . . 33
Figure 3.7 Front view of the rolling pad . . . . . . . . . . . . . . . . . . . 33
Figure 3.8 Leg of Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Figure 3.9 Side view of the base support . . . . . . . . . . . . . . . . . . . 34
Figure 3.10 X-axis movement part . . . . . . . . . . . . . . . . . . . . . . 35
Figure 3.11 Y-axis support . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Figure 3.12 Z-axis Gantry . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Figure 3.13 Side view of Spindle . . . . . . . . . . . . . . . . . . . . . . . 36

x
Figure 3.14 Initial CAD model of CNC machine . . . . . . . . . . . . . . . 37
Figure 3.15 Final CAD model of CNC machine . . . . . . . . . . . . . . . . 37
Figure 3.16 Stress Analysis using solidworks . . . . . . . . . . . . . . . . . 38
Figure 3.17 Strain Analysis using solidworks . . . . . . . . . . . . . . . . . 38
Figure 3.18 Strain Analysis using solidworks . . . . . . . . . . . . . . . . . 39
Figure 3.19 Graph showing bell curve form for velocity, acceleration, and
jerk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Figure 3.20 Stepper Motor simulink model . . . . . . . . . . . . . . . . . . 44
Figure 3.21 Graph showing angular position in full rotation . . . . . . . . . 45
Figure 3.22 Graph showing stepper linear motion - 5s- 20cm - 4000steps . . 46
Figure 3.23 Control Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Figure 3.24 Pin configuration Of DM542 . . . . . . . . . . . . . . . . . . . 48
Figure 3.25 Limit switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Figure 3.26 MACH 3 controller . . . . . . . . . . . . . . . . . . . . . . . . 49
Figure 3.27 MACH3 software interface . . . . . . . . . . . . . . . . . . . . 50
Figure 4.1 Bed of CNC Router . . . . . . . . . . . . . . . . . . . . . . . . 57
Figure 4.2 Base and water tub of CNC Router . . . . . . . . . . . . . . . . 57
Figure 4.3 Drainage system of CNC Router . . . . . . . . . . . . . . . . . 58
Figure 4.4 Stepper Motor used in CNC Router . . . . . . . . . . . . . . . . 58
Figure 4.5 Ball bearings used in CNC Router . . . . . . . . . . . . . . . . 59
Figure 4.6 Linear rails used in CNC Router . . . . . . . . . . . . . . . . . 59
Figure 4.7 X-axis of CNC Router with actuator . . . . . . . . . . . . . . . 60
Figure 4.8 Y-axis of CNC Router with actuator . . . . . . . . . . . . . . . 60
Figure 4.9 Z-axis and spindle of CNC Router . . . . . . . . . . . . . . . . 61
Figure 4.10 Control panel of CNC Router . . . . . . . . . . . . . . . . . . . 62
Figure 4.11 Testing of CNC Router . . . . . . . . . . . . . . . . . . . . . . 62
Figure 5.1 Initial design (Left) and Finalized design (Right) of CNC Router 63
Figure 5.2 1st testing on wood workpiece . . . . . . . . . . . . . . . . . . 63

xi
Figure 5.3 2nd testing on marble workpiece . . . . . . . . . . . . . . . . . 64
Figure 5.4 Final testing on marble workpiece . . . . . . . . . . . . . . . . 64
Figure 5.5 Measurements taken from different tests . . . . . . . . . . . . . 65

xii
 List of Tables

1.1 Cost per component . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.2 Timeline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 List of CAD software and their details . . . . . . . . . . . . . . . . . . 14
2.2 List of CAM software and their details . . . . . . . . . . . . . . . . . . 15
2.3 Specifications of CNC Router . . . . . . . . . . . . . . . . . . . . . . 24

xiii
 Nomenclature
AC → Alternating Current
CAD → Computer Aided Drawing
CAM → Computer Aided Manufacturing
CNC → Computer Numerical Control
DC → Direct Current
HMI → Human Machine Interface
IC → Integrated Circuit
kW → kilo Watt
NC → Numeric Control
RPM → Revolution Per Minute

xiv
 Chapter 1
Introduction
Numeric Control (NC) refer to the automated control of a machine using symbolic
and sequential codes that have characters and numerals. In the late 1940s, John Par-
sons of Parsons Corporation in Traverse City, Michigan, developed a system to control
machining equipment by feeding it punched cards with holes corresponding to coordi-
nates. The word CNC came into existence when microprocessors and microcomputers
replaced integrated circuit IC based controls used for NC machines. [1]

1.1 Computer Numerical Control (CNC)

A CNC machine is motorized numerical control system that has specified computer
for the control to do basic and advanced NC functions, according to input instructions.
Instructions are delivered to CNC machine in the form of sequential program such as
G-code and M-code. The program can be written by a person or can be generated using
graphical computer-aided design (CAD) software.
Modern CNC machines have mechanical parts highly automated. The part’s mechani-
cal dimensions are defined using CAD software and then translated into manufacturing
directives by computer-aided manufacturing (CAM) software such as MACH3. The re-
sulting directives are then transformed into the commands necessary for the production
of specific component and then are passed to the CNC machine.

1.1.1 Types of CNC machines:

Different types of CNC machines used in industry are as follow:

• CNC Milling
• CNC Router
 Introduction

• CNC Lathe
• CNC Plasma Cutter
• CNC Water Jet Cutter
• CNC Electric Discharge Machining (EDM)
• CNC Multi- spindle Machining
• CNC LASER Engraver

1.1.2 Classification of CNC machines:

CNC machines are classified on the bases of:

• Motion type.
• Control Loops.
• Number of Axis.
• Power Supply.

1.1.3 Applications of CNC machines:

CNC machines are utilized in many Metal removal industries such as automotive indus-
tries, aerospace industries and in making adornments. There are several industries that
require thin metal plates such as steel plates, for finished results. Metal fabrication tasks
such as drilling of holes, plasma cutting and welding have been made easier with CNC
machines. CNC machines are utilized to make barrels, ammunition clips, pins, trig-
gers, and several components of the weapons. CNC machines can likewise be applied
in wood working industry, lettering and engraving frameworks, electrical industry, the
pharmaceutical industry, food and drink industry, and marble industry.

1.1.4 Advantages of CNC machine:

• High repeatability, accuracy and precision.

• No possibility of human error.
• Complex shapes can be achieved easily.

2
 3-AXIS CNC MARBLE CUTTING AND CARVING MACHINE

• Production rate is higher.

• Uniformity in designs.
• Safe to operate and reliable.

1.1.5 Disadvantages of CNC machines:

• Trained operators are required to operate the machine.

• In case of breakdown highly skilled professionals are required to solve the problem.
• CNC machines are expensive and their maintenance are difficult.

3
 Introduction

1.2 Problem Statement

Pakistan is the 6th largest extractor of marble and granite in the world but contribution
of Pakistan in international stone industry is only 0.06 percent. Modern processing tech-
niques can add value to the raw marble but due to lack of financing activities processors
have not been able to do so for this purpose modern affordable automated machines
are very necessary for the betterment of Pakistan’s marble industry. For this purpose,
our aim is to design and fabricate an affordable CNC machine for marble cutting and
carving that work efficiently and have higher production rate in lesser time.

1.3 Motivation

The motivation behind doing this project was to modernize processing techniques used
in Pakistan’s marble industry. As Pakistan is a hub of marble and granite but unfortu-
nately we are unable to produce quality products therefore, to add value in our products
and make Pakistan’s industry progressive we opted this project.

1.4 Objectives

The main objectives of the project are:

1. To design and fabricate 3-axis CNC Router.
2. To cut and carve of 2D marble profiles.
3. To automate CNC tool positioning system.

1.5 Scope

• Design and fabrication of a 3-axis CNC router for marble cutting and carving, having
bed size 2ft x 2ft.
• Operates upon stepper motors to control the X Y gantry and the spindle, hence can
work in x, y and z axis.

4
 3-AXIS CNC MARBLE CUTTING AND CARVING MACHINE

• Water as a coolant is used for lubrication of the workpiece and reduces build up heat
and dust in the cutting and carving of marble. • Mach 3 software is used as a motion
controller.
The CAD/CAM software used for G-code preparation is an open source software.
• Cut and carve shapes on raw marble efficiently.

1.5.1 Limitations:

• Router’s spindle can not automatically change tools, it can be done manually.
• Router has to be restart manually if stopped during working.

5
 Introduction

1.6 Cost Analysis

The component which are required for the project and their Price is given in the table
below. With the total cost of the project.to be around 170,000 RS. The price can vary
from one buyer to another.

Table 1.1: Cost per component

Components Per unit cost (Rs) Net cost (Rs)

Stepper motor for x,y,z axis 6,500x3 19,500

Spindle cost 15,000 15,000

Bed Fabrication cost 20,000 20,000

Bed Material cost 20,000 20,000

Motor Drivers 8,000x3 24,000

Linear rails 5,000x6 30,000

Lead screws 1,650x3 4,950

Miscellaneous tools 10,000 10,000

Wiring + emergency stops 4,000 4,000

Water Pump 6,000 6,000

Controller Card 6,000 6,000

Power supply 5,000 5,000

Auto-calibration sensors 5,000 5,000

Total approx. cost 169,450

6
 3-AXIS CNC MARBLE CUTTING AND CARVING MACHINE

1.7 Timeline:

In order to complete the project, it is important to devise a time plan. The time is divided
into to proportions. Each task requires certain amount of time for its completion.

Table 1.2: Timeline

Elapsed time Milestone Deliverable

1 month approx. Literature Review Scope of Project

2 months approx. Finalizing materials Manufacturing scope

3 months approx. Initial CAD model CAD model of project

6 months approx. Engineering design calculations Mathematical model

8 months approx. Hardware implementation Mechanical structure

11 months approx. Installing Firmware Software setup

12 months approx. Final Testing Fully functional project

1.8 Organization of Report

7
 Chapter 2
Description
CNC routers are commonly mounted on a fixed table with a bigger workspace, high-
lighting a shaft that moves along axis– X, Y, and Z. CNC Routers are intended to work
at high speeds , utilizing rotational speed as driving force in making cuts. Routers nor-
mally have three axis, there are varieties with 4-6 axis that are perfect for progressively
complex tasks. The force behind any Routers is its CAD/CAM programming. The CAD
programming permits the client to make a plan they need the router to cut. When this
plan has been made, the CAM programming changes over the structure into a code that
the router can comprehend. The PC at that point makes an interpretation of this code
into signals that control the development of the router’s drive framework. The drive
framework contains the shaft, which is the part that holds the genuine router bits. The
shaft turns these bits 8,000 to 50,000 times each moment so as to cut the material. [2]
3-axis CNC routers cut along three axis simultaneously; the x-axis, the y-axis, and the
z-axis. Cutting along the x-axis moves the router bit from front to back, cutting along
the y-axis moves it from left to right, and cutting over the z-axis moves it in depth. These
machines are utilized fundamentally for cutting level, 2-dimensional parts. [3]

Figure 2.1: Basic image of CNC Router

 3-AXIS CNC MARBLE CUTTING AND CARVING MACHINE

2.1 Literature Review

In this section we will discuss the past work of various authors who have attempted
to design and construct the smaller CNC machines. CNC technology has a signifi-
cant contribution in industries today. CNC machines are the main forum in industry
for contributing high quality goods. CNC machines are essentially automatic operating
machines based on letters of code (NC etc.), numbers and special characters. The nu-
merical data required to manufacture a machine-supplied part is called CNC (Computer
Numerical Controlled).

In 2010, Venkata Krishna pabolu et al. published a research paper on the de-
sign and implementation for industrial application of low-cost, three-dimensional
computerized numerical control system (CNC). [4] In this paper prototyping an Em-
bedded CNC machine was created. This microcontroller-based CNC machine has the
primary function of cutting the metal in the required shape. This article focuses on
contact between a PC and a numerical control unit. The aim of designing a computer-
controlled cutting machine stemmed from the increasing demand for flexibility and cut-
ting in terms of edge quality. The system has an 8 bit microcontroller based embedded
system to achieve cost effectiveness and also maintains the precision and reliability re-
quired for complex shapes. The core of the system, along with the embedded system,
is a cleverly built mechanical device that results in precision. The system uses C as the
user interface programming language and .NET platform.

In 2017 , a research paper published in International Journal of Applied Engi-

neering Research by R.Ginting1 , S. Hadiyoso 2 and S.Aulia on Implementation
3-Axis CNC Router for Small Scale Industry. [5] This paper addresses the design
and implementation of complex microcontroller-based 3-axis CNC machines combined
with spindle drilling. The tool can be used on wood, acrylic and PCB items for cutting,
engraving, and marking. Model image was sent to the controller on the PC by using se-
rial communication, then CNC performed execution according to the coordinates. Drill
spindles will create patterns on objects according to the drawings. After checking, the
CNC machine can be used on wood, acrylic and PCB to 2D & 3D objects with 98.5%
accuracy and 100% depth accuracy for cutting and engraving . Multiplex board, stepper
motor, linear bearing, ball bearing, linear shaft, leadcrew and nut, coupling beam, power
supply and spindle drill are the main mechanical design tools. 3D CNC machine design
made using AutoCad software. The accuracy test was performed to determine the level
of CNC machine accuracy in form making. This test input was a pattern of 6 lines with

9
 Description

a length of 50 mm, to be built on a 1 mm deep wood. Using 3 mm drill bit vbit600 with
a spindle speed of 12000 rpm and 98.5 percent accuracy output. [5]
The engraving system was tested on a 20 mm thick wood, using 600 drill bit 3 mm vbit,
12000 rpm spindle speed and 7 mm engraving depth. Picture design using Vetric Aspire
8.5 software, examples of design using engraving pattern combined with writing.
The speed test was performed to determine the effect of angle on velocity in the shape
of material. The input for this test was a 10 cm long line pattern that will be formed to
resemble some 2D shape. With 1mm engraving depth on wood using 3mm endmill drill
bit.
The CNC router was successfully designed using ATmega328p and IC4988 microcon-
trollers together with 3 Nema 17 stepper motors, 20x20 cm cross-sectional area and
500-Watt Spindle Air Cooled drill type. The CNC machine can be used to carve, en-
grave and label on wood to shape 2D or 3D objects with 98.5 percent carving accuracy
and 100 percent depth accuracy. [5]

In January 2019, an article published in International Journal of Innovative Re-

search in Advanced Engineering by Suharto, Kunto Ahmad [6] about Enriching
Creative Engineering products as High Quality and Competitive with Marble stone ma-
terials. The results of the research can be concluded as:

1. CNC Machine Router 3-Axis machining parameters for engraving granite and
marble stones are: 30 (m / min) cutting speed, 12000 (rpm) spindle rotation, and
2000 (mm / min) feed rate. Analysis of the factors affecting the surface roughness
of the first marble gravure is the speed / rate of the intake, the depth of the intake
means the higher value, the higher surface roughness of marble.

2. The 3-axis CNC system for making aluminum molds uses various supporting
softwares, before being executed by MACH3,namely CorelDraw, Aspire Vectric.
Mach3 is an Art Fenerty device found in 2001, and developed by ArtSoft. This
program works while running a 3-axis CNC router system to execute all driver
commands. The Mach-3 program can order this, namely stepper motor (axis mo-
tion) movement in the form of G / M code, spindle rotation and speed, limit trans-
fer settings, relay settings, and emergency stop settings. These commands form
the basis for programming a 3-axis CNC router, making Mach3 software the main
programming software for 3-axis CNC router machines. [6]

10
 3-AXIS CNC MARBLE CUTTING AND CARVING MACHINE

In 2015, Bhargav Prajwal Pathri published a book “Study analysis of various mar-
ble cutters used in stone and marble Industry of Rajasthan” [7] in which he con-
cluded that:
Stone cutting with diamond segmented saw blades is a process of machining that rep-
resents a significant cost item for processing marbles and other natural stones. The
performance parameters, characteristics of the saws are affected by a range of factors
that are mechanical and physical properties of stone material, petrography properties
of stone materials, applied technological parameters, properties of machines, properties
of tool and machining methods. However, the main factors that require consideration
when predicting sawing rates are the diamond saw types, saw operating parameters, and
the sawn rock properties. For this reason , it is important to know the composition of
the tool bits used to cut the stones for this FESEM (Field Emission Scanning Electron
Microscope), EDS (Energy Dispersive Spectroscopy) and XRD (X-Ray Diffractometer)
analysis for specimens of tool segments (matrix and diamond) collected from various
stone industries by industrial survey in and around Rajasthan to determine the optimum
sawing conditions. The results showed that the material percentages in bits are used
to cut low hard marble stones (Fe-41 percent, Co-7 percent, Si-6.82 percent, Ni-13.82
percent, C-7 percent) and to cut hard marble stones (Fe-3.19 percent, Co-33.05 percent,
Si-7.35 percent, Ni-0.03 percent, C-6.71 percent) and hard marble stones.

11
 Description

2.2 Methodology
First, study of previous work (literature review) on CNC marble cutting routers has been
done. After that initial modeling of a CAD design using Solidworks has been done,
which helped a lot in making a stable and compact design of CNC router. The next step
was Engineering design calculations, after that final modeling of CAD design had done.
Then, implementation on hardware was executed, which begun from X,Y Gantry and
initial testing was done on wood as workpiece.Then limit switches was applied for the
control of router.Finally Firmware was installed which is an open source firmware and
the software for G-code preparation was also installed for final testing on marble.

12
 3-AXIS CNC MARBLE CUTTING AND CARVING MACHINE

2.3 CNC ROUTER for Marble cutting and Carving

Stone cutting CNC routers are designed for marble, granite, artificial stone, tombstone,
metal and different stones need different specific bits and tools. There is a specific bit
called “Diamond tools” having different diameters such as 4mm, 6mm are mainly used
for cutting and carving purpose. This routing process is more like grinding than cutting.
In this project we have designed CNC Router specially for marble cutting and carv-
ing.Special bits are used along with tool holders to carve hard marble. Water pump is
attached for water to use as coolant.While cutting or carving the marble a lot of friction
built up heat along with dust and debris of marble which doesn’t allow to carve and
finish the workpiece properly therefore, water will decrease the temperature and settle
down all the dust so as marble dust is very abrasive and for better protection it is neces-
sary. As well as the router is designed with full safety having underneath water tub for
used water drainage.

2.4 CNC Router Operation Flow

13
 Description

2.5 CNC Router Block Diagram

2.6 CAD Software:

Computer Aided design (CAD) software is used in designing machinery parts in 3D and
2D drawings. It also provides the features of modification, optimization and analysis
of the model. CAD software improves the productivity and quality of the design. CAD
software is used by architects, engineers, industries and designers to create mechanical
structures.There are different applications of CAD softwares which are either free for
user or payed. Some mostly used application are listed below.

Table 2.1: List of CAD software and their details

S/N CAD Software Operator Level License

1 Free CAD Beginner level Free
2 Creo Intermediate level License: $ 2310/lifetime
3 Fusion360 Intermediate level Free for students and academic
Institutions
4 Solidworks Professional level License: $3995/lifetime
5 AutoCad Professional License $ 1470/year
6 OpenSCAD Professional level Free
7 Rhino Professional level license €995/year

14
 3-AXIS CNC MARBLE CUTTING AND CARVING MACHINE

2.7 CAM software:

Computer aided manufacturing (CAM) is a software which facilitates and automates
manufacturing process. It also provides real time control of the model. CAM gives an
ease in designing and controlling the model. CAM software is basically a tool/program
that uses CAD design to create detailed instructions program (G-code) that drive CNC
machines.

Table 2.2: List of CAM software and their details

S/N CAM Software Price

1 BobCad Licensed $2000/one time
2 Fusion 360 Licensed $450/year
3 Solid Edge CAM Pro Licensed $350/month
4 Solidworks CAM Licensed $2400/year
5 LinuxCNC Free
6 CAMotics Free

2.8 Programming Language:

2.8.1 G code:

G code is also preparatory code or we it is a language which consists of different codes.

G code are instruction which tell the machining tool how to operate or in simple words
how to cut the through a material. It tells the tool how fast to move, which track to fol-
low, where to position the cutting tool, etc. every line in a G code starts with the letter
G and then some numbers defining what task to do.
Some basic G codes are as following:

G code Description
G0 Rapid positioning
G1 Linear interpolation
G2/G3 Clockwise/ Counterclockwise helical interpolation
G4 Dwell/ makes the machine stop
G12/13 Circular Clockwise/ Counterclockwise pocket
G20/G21 Inch/Millimeter unit

15
 Description

Example code:
G90 Absolute positioning
G20 Selecting millimeters as dimension unit.
G0 X0 Y0 Z0 It will rapidly move the tool to (0,0,0) coordinates)
G1 X60 F100 Moves to (60,0,0) with federate of 100mm/mint
G1 Z-3 F50 Tool moves 3 units down in z axis at a speed 50mm/mint

These codes are manually written and saved in a file as note or document and then
through USB are fed to the CNC machine programing unit, which then executes the
code.

2.8.2 M code:

M code or milling code are commands for the cutting tool which through commands
make the spindle start/stop, cut in clockwise or counter-clockwise direction.
Some M-codes are:

M code Description
M2 Ends the program
M3/M4 Starts spindle c/ccW
M5 Stops the spindle
M6 Tool change
M7 Turns the coolant ON
M47 Repeats the code from first line.

16
 3-AXIS CNC MARBLE CUTTING AND CARVING MACHINE

2.9 Motion Controller Card

Control cards control the motors and software to communicate and follow the instruc-
tion according to G-code commands.Controller used in this router is MACH 3 however,
list of different control cards for CNC Routers are listed below:

Figure 2.2: Different controller cards for CNC Routers

17
 Description

2.10 Components Description

2.10.1 Stepper Motor:

Bipolar stepper motor is used for the axis movement.Stepper motor is used in this project
due to its lower cost and great efficiency, rather than using servo motor which is of high
cost and has a accuracy slightly greater then stepper motor.By using stepper motor’s
poles we can achieve that accuracy almost upto 95%.

Figure 2.3: Stepper Motor

2.10.2 Water pump:

A water pump is used to provide water to cutte, which is an essential coolant for marble
cutting as it carries away the residue and provides ease for the cutter to perform its task
by reducing build up heat due to great friction. Water also helps to add finish to marble
cuts.

Figure 2.4: Water Pump

18
 3-AXIS CNC MARBLE CUTTING AND CARVING MACHINE

2.10.3 Bed:

Bed size includes the working area or work piece area and the outer layer on which the
work piece is resting on. The actual work area of machine (bed) is 2x2 ft.

Figure 2.5: Bed of CNC machine

2.10.4 Ball screw rods:

Ball bearing roads contain small little balls in the sliding sockets. As rolling surface
faces less friction as compared to sliding surface. So ball bearings are used in the CNC
router. Ball bearing rods are attached to the stepper motors that leads all the movement
in our x y and z axis.

Figure 2.6: Ball screw Rod

19
 Description

2.10.5 Linear Rails:

Instead of using linear rods, linear rails are preferable as they can hold more load as
compared to rods. Rods also bend much when load is applied and are not ideal for the
CNC machines. Rails provide a smooth flow, large load capacity and a stable platform.

Figure 2.7: Linear Rails

2.10.6 Spindle:

A spindle contains a motor attached in side which can vary from 1.5kW to as much
power as required.Router’s spindle is the main part as it holds the cutting tools and it
provides angular velocity and torque which then is derived to cut the marble.

Figure 2.8: Spindle

20
 3-AXIS CNC MARBLE CUTTING AND CARVING MACHINE

2.10.7 Emergency Stop:

Emergency stop button is an important safety measure for every machine that has a
moving part in it. A CNC operates at high voltage as well as high speed. In order to
stop the machine in any hazard stop button is easy to reach. When the button is pressed
the machine’s rotating part immediately stops.

Figure 2.9: Emergency stop Button

2.10.8 Auto Calibration Sensor:

To calibrate the position of the tool we can either do it manually every time or place a
sensor to make the machine completely autonomous. We used a sensor which guides
the machine about its X, Y, and Z coordinates. The head of the spindle collides with the
sensor indicating the coordinates in the plane.

Figure 2.10: Auto calibration Sensor

21
 Description

2.10.9 Tools and Tool Holders:

In CNC different tools are used for different operation because one tool is not enough to
perform all the task therefore, in order to have a solid grip on the cutting tool different
types of tool holders are available, that holds the tools firmly and not allow any move-
ment.
HSK Tool Holder:
HSK tool holder is a German product. It is known for its unique feature. One side of the
holder is fixed while the other is tightened. It provides an excellent grip and precisely
firm position, which is necessary. As a small run out can ruin our workpiece and even
can break the tool.

Figure 2.11: HSK tool holder

2.10.10 Cutting Tools:

In order to get our required shape or design on the marble we use different tools as one
tool cannot fulfill all requirements therefore tools for milling, drilling and facing pur-
poses are different. And they also differ for different materials due to their toughness.
For marble cutting, most of the tools used are made up of diamond, graphite or stone .

Figure 2.12: Bits for cutting and carving marble

22
 3-AXIS CNC MARBLE CUTTING AND CARVING MACHINE

Figure 2.13: List of tools for cutting and carving

23
 Description

2.11 Product Specification

Table 2.3: Specifications of CNC Router

Machine Size 3 x 3 ft
Working Area 2 x 2 ft
Material Hard steel & Aluminium
Height 1.7 ft
Degrees of freedom 3 ( x, y, z axis)
Spindle Power 1.5 KW
Weight 85 kg
Axis Drives Stepper 3A, Step angle =1.8 deg
Controller MACH 3
Power Requirements 220V AC, Single Phase
Operations Cut & Carve Marble

2.12 ISO Standards

1. ISO/TS 14649-201:2011(en): Industrial automation systems and integration — Phys-
ical device control — Data model for computerized numerical controllers — Part 201:
Machine tool data for cutting processes.
2. ISO 229:1973 – This standard specifies the speeds and feeds of CNC machines.
3. ISO 369:2009 – Certain symbols and depictions can be found on the body of CNC
machines. These symbols and their corresponding meanings are specified in this stan-
dard.
4. ISO 14649-1 apply: executable, machining operation, NC function, working step. [8]

24
2.13 Engineering Design Calculations
Calculations for Lead Screw

2.13.1 Calculating Lead screw forces:

For calculating Lead screw forces we have to encounter:

-Weight of assembly to be moved by the lead screw
-Desired linear velocity of assembly
-Desired time to reach velocity (acceleration)
-Linear Bearing type of assembly (ball bearing, sliding bearing)
Formula used for the total lead screw forces:

2.13.2 Calculating force due to acceleration:

 Description

2.13.3 Calculating force due to friction:

2.13.4 Calculating external forces:

No external forces acting on the system.Therefore,

2.13.5 Total Lead screw force:

Adding all lead screw forces total force calculated :

2.13.6 Calculating Lead screw inertia:

26
 3-AXIS CNC MARBLE CUTTING AND CARVING MACHINE

Calculations for Motor Torque

Motor torque depends on friction torque and acceleration torque. Motion profile of a
stepper motor is shown in graph.

2.13.7 Calculating friction torque :

2.13.8 Calculating acceleration torque:

27
 Description

2.13.9 Calculating load inertia:

2.13.10 Motor Torque:

Putting all values calculated motor torque:

Applying safety factor of 1.5 final motor torque calculated:

Calculations for Spindle:

2.13.11 Calculating cutting speed:

28
 3-AXIS CNC MARBLE CUTTING AND CARVING MACHINE

2.13.12 Calculating spindle speed:

2.13.13 Calculating feed rate:

2.13.14 Calculating drive motor torque:

29
 Chapter 3
Modeling and Simulations
3.1 CAD MODELING:
CAD (Computer Aided Design) Model is basically a software based design that helps
with mechanical design and precision drawing. We used to represent the models as they
will behave in real life. When we pre-designed models the design and manufacturing
becomes simple, which not only facilitates the production of the product but also gives
it a wide range of enhancements. If we have the exact framework that we need for the
project then we push onto the implementation of the hardware. Below are the CAD
MODEL parts made for thCNC Router in SOLIDWORKS:

3.1.1 Base:

The base of the CNC is of 3x3 ft. Rods at the center of the base are designed to support
the work area, designed along with a tub to collect and drain water.

Figure 3.1: CAD design of CNC Base

 3-AXIS CNC MARBLE CUTTING AND CARVING MACHINE

3.1.2 Bed:

The bed or the working area of router is 2x2 ft. which will support marble pieces for
carving. The bed has fringes which will hold the marble pieces with grippers to prevent
vibration and damage.

Figure 3.2: Side view of bed

3.1.3 Linear Rails:

The structure of the rail is shown below. The height and width of rail is 6cm each. The
length of rail in X axis is 96.6 cm. The holes on top are done through hole wizzard
which are at 5cm apart from each other. For Y axis the length of the rail is:

Figure 3.3: Front view and dimension of rail

31
 Modeling and Simulations

3.1.4 X-Rail Bracket:

Using the rail structure dimension a bracket is designed that will slide on the rail. It also
be supports Y and Z frames. The bracket is 8 cm wide and has height of 6 cm. Its total
length is 15 cm.

Figure 3.4: Front view of X Rail

3.1.5 Y axis Rail Bracket:

The Y axis bracket is same as X bracket. Its width is larger in size only. Its width is
15cm and dimension along the top are 15x15 cm.

Figure 3.5: Drawing and dimension of Y bracket

32
 3-AXIS CNC MARBLE CUTTING AND CARVING MACHINE

3.1.6 Ball bearing Rods:

The rods are attached to support the load on X gantry and provide steady movement.
The rods are 3 ft long with diameter of 2.5 cm.

Figure 3.6: Ball bearing rod side view

3.1.7 Bearing Rod Pad:

The rolling pads are of 5.5 cm high and 6 cm wide having inner radius of 2.5 cm with 5
cm length. The thread inside is of 2.5 mm. They provide less friction due to movement
of little balls packets.

Figure 3.7: Front view of the rolling pad

33
 Modeling and Simulations

3.1.8 Base support/ Legs:

The Base of CNC is supported by 4 legs on which the ball bearing rods are attached. Its
total height is 25.4 cm and its with is 16.6 cm and is extruded upto 5 cm. Rods are held
at 15.2 cm apart.

Figure 3.8: Leg of Base

Figure 3.9: Side view of the base support

34
 3-AXIS CNC MARBLE CUTTING AND CARVING MACHINE

3.1.9 X Gantry movement plate:

The X movement plate is the main moving plate. It is 110.6 cm wide. It has a circle in
the center of radii 40 cm which is for the X axis stepper motor. The sides are 4cm wide
and attached with linear rails.

Figure 3.10: X-axis movement part

3.1.10 Y axis Support:

The Y support if 1.5 ft in length. It is to support the rail on Y-axis and the Y-axis ball
bearing rod have diameter of 3 cm. The width of the support is 15 cm so it is of the same
length as of X movement plate. The sketch is extruded to 4cm.

Figure 3.11: Y-axis support

35
 Modeling and Simulations

3.1.11 Z-axis Gantry:

Z-axis gantry contains ball bearing Rods of 3 cm dia. The height of the rods and the
holding plate is 1.3 ft long and 19 cm wide. The same rolling pads used in X gantry are
attached to it.

Figure 3.12: Z-axis Gantry

3.1.12 Spindle:

This is the representation of the spindle. The spindle size is kept ideal in CAD model.
The spindle has outer diameter 7 cm and inner of 5 cm. Designed to support a heavy
KW motor as required for marble cutting. The length of motor attached to spindle in 8
cm.

Figure 3.13: Side view of Spindle

36
 3-AXIS CNC MARBLE CUTTING AND CARVING MACHINE

3.2 CAD MODEL:

Figure 3.14: Initial CAD model of CNC machine

Figure 3.15: Final CAD model of CNC machine

37
 Modeling and Simulations

3.3 Stress and Strain Analysis:

Figure 3.16: Stress Analysis using solidworks

Figure 3.17: Strain Analysis using solidworks

38
 3-AXIS CNC MARBLE CUTTING AND CARVING MACHINE

3.4 MATLAB/SIMULINK MODELING:

The mathematical modeling for our CNC was accomplished using MATLAB and Simulink.
Our main focus during this was to control the rotation of the stepper motor, which can be
translated into linear motion of the axis via simple arithmetic involving the screw pitch,
as well as calculate the effects of damping by various elements of the construction, such
as bearing friction and weight etc.

3.4.1 Introduction:

A hybrid stepper motor works by having two sets of windings (let’s call them A and B)
magnetizing sets of teeth that are either fully aligned, half-aligned, or unaligned with the
teeth of the permanent magnet in the center. The windings are powered one at a time
in sequence to achieve a step (e.g. A in one direction, B in the same direction, A in the
opposite direction, B in the opposite direction). [9]

Figure 3.18: Strain Analysis using solidworks

This is handled using a stepper motor driver that receives a pulse input, and deter-
mines what alignment of the magnets is necessary at a given step to move to the next one.
Therefore, we only need to determine how many pulses are needed at a given time; i.e.,
we need to determine the pulse frequency required for it to move on a stable path. By
our initial calculations of safety bounds, we have determined that a maximum rotational
speed of 400 rpm is adequate for our purposes. Keeping within this limit, we determined
a formula based on modelling DC motors for stable functionality, and finding the steps
required to achieve the (near-)equivalent rotation in stepper motors.

39
 Modeling and Simulations

3.4.2 Motion Profile:

DC motor control requires control over the position, the velocity, the acceleration, and
the jerk of the motion. To do this we use a polynomial equation where we can specify
two end values for each (i.e., an initial and a final value). We use a seventh order
polynomial to achieve this; the solution for a seventh order polynomial requires us to
specify 8 values, or two for each.
The graph that we derive using these polynomial equations is known as a motion profile,
which helps us find the magnitudes of the coefficients at any moment in time, which is
useful while determining the viability of the motion of the motor. Any irregularities,
errors, or potentially unwanted spikes can be corrected due to the information provided
by these plots.
A MATLAB function takes these values as an input, and solves the polynomial for the
coefficients that fulfil those conditions.

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 3-AXIS CNC MARBLE CUTTING AND CARVING MACHINE

After this function is complete and the coefficients have been computed, they are
used to calculate the motion profile of the motor’s current motion, modeling for the pre-
viously mentioned variables. These can be converted, for a simple case with no damping
or friction, to linear motion along an axis by simple multiplication of the angular position
with the screw pitch. This can be done in the opposite direction as well; by determining
the linear motion’s parameters and dividing it by the pitch, we can find the relation to
the angular motion of the motor, which is what has been done.

For example, the following set of parameters achieve this result:

41
 Modeling and Simulations

Figure 3.19: Graph showing bell curve form for velocity, acceleration, and jerk

The components’ magnitudes can be controlled at different points in time by calcu-

lating for the new coefficients and plotting them in the new time period that has been
divided into new sections. This does result however in more fluctuations between peri-
ods overall.

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 3-AXIS CNC MARBLE CUTTING AND CARVING MACHINE

3.5 Simulink Modeling:

To implement into stepper motors, we need to determine the frequency of the pulses
(hence the speed of rotation and the angular displacement) to provide to the motor. To
this end, we measure the velocity at quarter-second (0.25s) intervals, and convert it to
the amount of pulses required using the following code, storing them in velpfeed:

Using this data in Simulink is tricky, since inputs cannot be updated during runtime
without special tools. To get around this we can pause the simulation at the required
timestep, update the value, and continue. An array containing compatible time periods
and amplitudes for the pulse generator block is created using the following code:

We used a MATLAB stepper motor setup to determine the variables (such as cur-
rent, voltage, angular velocity, torque, etc) within limit.

43
 Modeling and Simulations

We implemented the stepper motor on the SIMULINK. As we are using same motors
NEMA 23 therefore all the motors will have same response.So we designed the simulink
of a single stepper motor. We have cheched the Current, velocity, torque and angular
speed of the motor using our initial conditions to run it on the model and to see its
output. The Simulink model is shown below. In which we have connected a motor
driver, stepper motor and have connected the outputs to a scope.

Figure 3.20: Stepper Motor simulink model

The stepper motor drive has eight terminals:

STEP: This functions as an ENABLE pin, i.e. when it is provided the positive Boolean
level it will call for the motor to rotate according to the inputs provided. When the neg-
ative Boolean level is provided instead it will call for the motor to cease rotation.
DIR: Determines the angular direction of the motor. When the positive Boolean level
value is provided it will call for the motor to rotate (if it has the permission to rotate,
via STEP) to rotate in the counterclockwise direction. When it is provided the negative
Boolean level value instead, it will call for the motor to rotate (again, checking STEP)
in the clockwise direction.
V+, V-: Voltage terminals for the driver, providing power to it for the driver’s own
functionality as well as that of the stepper motor.
A+, A-, B+, B-:Two sets of terminals that correspond to the winding terminals in the
stepper motor. Each needs to be connected to the respective terminal. The function of
the driver is to power these terminals in the right order at the right intervals, for which
it uses hysteresis-based controllers that oversee two H-bridges.

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 3-AXIS CNC MARBLE CUTTING AND CARVING MACHINE

The stepper motor has five input terminals:

Load Torque: Simulation tool to specify how much torque the stepper motor will be
receiving.
A+, A-, B+, B-:The terminal ports for the stepper motor windings. The output of the
stepper motor is a bus which contains multiple types of data.

3.5.1 Simulation results:

We started by setting the stepping speed to 40 steps per second, and ran the simulation
for a sample time of 0.25 seconds. This test was to determine the functionality of the
stepper motor model.
Over a period of 0.25 seconds, there occured 40 steps/s*0.25 seconds = 10 steps. The
angles move through ten new stages from 0 to 9, as described by the number of plateaus,
including a step that isn’t visible at the top right that pushes the y-graph up to step 9.
The maximum value is 1.8deg / 360 (deg/rot) * 9 = 0.045 rot.

Figure 3.21: Graph showing angular position in full rotation

45
 Modeling and Simulations

After that initial experiment, we used the scope to study the behaviour of the stepper
motor in response to our input steps.
For our final test we simulated a full length motion of 20 cm over 5 seconds, for which
we required (20cm / (360 deg / 1.8 deg/step) ) = 4000 steps, or 800 steps per second.
The results are given in graph below.

Figure 3.22: Graph showing stepper linear motion - 5s- 20cm - 4000steps

46
3.6 Control and Calibration
The CNC controller is the brain of CNC machine as it completes link between HMI
panel and mechanical structure of CNC machine. Controller’s primary task is to take
input from HMI panel and interpret the input into mechanical motion.There are several
components that make the control system includes:

1.Controller
2.Motor drivers
3.Power supply unit
4.Limit Switches

Figure 3.23: Control Parts

 Modeling and Simulations

3.7 Microstep driver DM542:

Microstep driver is a stepper motor driver which controls the stepper motors. It gives
the direction and number of pulses for the motor to move. It is mainly connected to
the mach3 controller. It can operated on 24 volt power supply. It has 8 switches out of
which first three are for current selection (max 4.2 amp) and remaining 5 switches are
for motor speed (max 25000 pulses/rev ).

Figure 3.24: Pin configuration Of DM542

3.8 Limit switch:

A limit switch is a electromechanical device used as industrial control component.When
anything gets in contact with actuator limit switch make or break the electrical connec-
tion.In CNC machine limit switch sends signal to controller that will stop axis trying to
move away from end range.

Figure 3.25: Limit switch

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 3-AXIS CNC MARBLE CUTTING AND CARVING MACHINE

3.9 MACH3 Controller:

MACH3 controller is the breakout board for CNC machine. It is used to control the
motion and direction of the stepper motors, you can connect up to 5 motors or 5 axis
can be controlled with it. It can further control the emergency switch along with the
limit switches which control the limit of how much one axis can move.It also controls
the spindle speed. We are using it to control 3 stepper motors for x, y and z axis along
with rest of the features mentioned previously.

Figure 3.26: MACH 3 controller

3.9.1 Features of MACH3 controller:

• Out voltage range.

• It provides high performance at a very cheap cost.
• Can support 5 axis stepper motors driver.
• Provides an USB and DVI port connection.
• Provides limit switch, CNC alignment and emergency stop.
• Can also control spindle, air pump or water pump.

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 Modeling and Simulations

3.9.2 MACH3 Software:

CAM software used is Mach3 software to control the CNC operation.MACH3 software
runs on a PC and turns into a powerful Machine controller to replace control unit.
It generates G-code file to run the CNC machine.
It controls the inputs and outputs of the motors, limit switches and emergency stops.
It is basic simple software to program the CNC machine and is user friendly.

Figure 3.27: MACH3 software interface

3.10 Calibration Method:

Calibration is done in order to make the CNC machine working precise according to
length and limits. For this ,once all the connection are made,it is time to calibrate the
CNC machine. Before we calibrate our CNC machine it is important to connect the DVI
PORT with mach3 controller and PC. Now to calibrate the respective motor.

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 3-AXIS CNC MARBLE CUTTING AND CARVING MACHINE

Do following steps to callibrate:

3.10.1 STEP 1:

Open MACH3 software and plug in the port in PC.

3.10.2 STEP 2:

Go to pin an config and select Pins and Ports.

3.10.3 STEP 3:

Select Port setup and axis Selection. Select the port 1 and set the speed and click on
apply.

51
 Modeling and Simulations

3.10.4 STEP 4:

Click on MOTOR OUTPUT. The ticks and cross represent as on or off.

Select all the motors being used are selected. Click on apply.

3.10.5 STEP 5:

Go to Input signals and set as shown. And click on apply.

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 3-AXIS CNC MARBLE CUTTING AND CARVING MACHINE

3.10.6 STEP 6:

Select output signals and set the following settings.

3.10.7 STEP 7:

Now we will set up the spindle using Spindle setup.

53
 Modeling and Simulations

3.10.8 STEP 8

Click on System hotkey and select the keys with which you want to move the motor
manually.

3.10.9 STEP 9:

Now we can calibrate the CNC by two methods, First is manually. MAnualy move the
CNC X axis motor to a certain position. Move 1 mm through the mech3 software. Now

54
 3-AXIS CNC MARBLE CUTTING AND CARVING MACHINE

measure the distance moved by the motor. If it is less or great then change value steps
pr in motor tuning till the distance traveled by the motor and being moved through the
system become precise.

Now repeat this step for Y and Z axis.

55
 Modeling and Simulations

3.10.10 Determining steps per unit length:

The second method to calibrate the axis is calculating the steps per unit length. By using
the formula.

Enter these calculated values and the motor will cover as required scale for move-
ment.

56
 Chapter 4
Experimental Setup
Based on the above described 3D design and calculations 3 axis CNC router for
marble cutting and carving has been fabricated with defined specifications.

4.1 Working Area (Bed) of CNC Router

The working bed is made with aluminum rails of 2x2 ft to support the work piece prop-
erly. Aluminium is used to avoid rusting. It can also support small pieces of marbles.

Figure 4.1: Bed of CNC Router

4.2 Base and Water tub of CNC Router

The base of the CNC Router is 3X3 ft and made with hard steel.As it is also the water
tub of the router for collecting and draining the water used during cutting and carving
of marble.Blue paint is applied to avoid corrosion.

Figure 4.2: Base and water tub of CNC Router

 Experimental Setup

4.3 Water drainage

A drainage whole is drilled under the bed of CNC and an L shaped metal pipe has been
attached which is further connected to another plastic pipe and can extended to any
length for exit flow of water.

Figure 4.3: Drainage system of CNC Router

4.4 Motors for 3 axis CNC Router

3 Steppers motors have been used to along X Y and Z axis. The steppers motors are 2.7
volts and 3 amps and step angle 1.8 degree. Which provides a 1.5Nm torque.

Figure 4.4: Stepper Motor used in CNC Router

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 3-AXIS CNC MARBLE CUTTING AND CARVING MACHINE

4.5 Ball Bearing Rods

Ball bearing rods contain little balls in the sliding sockets to male rolling surface faces
less friction as compared to sliding surface. Ball bearing rods will be attached to the
stepper motors which will lead to all the movement in our X Y and Z axis.

Figure 4.5: Ball bearings used in CNC Router

4.6 Linear rails

Linear rails have been used in pairs to make hold the three axis and to provide them
frictionless movement across the CNC, Rails are preferable as they can hold more load
as compared to rods. linear rails have been used of 3ft across X and Y axis and a 6inch
along Z axis.

Figure 4.6: Linear rails used in CNC Router

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 Experimental Setup

4.7 X axis of CNC Router

X axis actuator is supported on linear rails of x-axis,which are providing the frictionless
sliding and a ball screw road is attached with the Stepper motor of 3 Amp. The total
working area along X axis is 1000mm.

Figure 4.7: X-axis of CNC Router with actuator

4.8 Y axis of CNC Router

Y axis actuator is supported on linear rails of y-axis, which are providing the frictionless
sliding and a ball screw rod is attached with the Stepper motor of 3 Amp, responsible
for the movement of y-axis. The total working area along Y axis is 1050 mm.

Figure 4.8: Y-axis of CNC Router with actuator

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 3-AXIS CNC MARBLE CUTTING AND CARVING MACHINE

4.9 Z axis and Spindle of CNC Router

Z axis actuator is supported on linear rails of z-axis, which are providing the frictionless
sliding and a ball screw rod is attached with the Stepper motor of 3 Amp, responsible
for the movement of z-axis. The total working area along z axis is 60 mm.
28-volt DC motor of 1.5KW power is used as a spindle, which is attached with holder
that holds it in place. The spindle supports 8 mm rotary bits and has RPM of 5000.

Figure 4.9: Z-axis and spindle of CNC Router

4.10 Control Panel of CNC Router

The control panel contains all the drivers, Mach3 controller power supply, relay switch
and AC filtration unit.
The 220 AC supply is filtered and connected to the power breaker and power supply.
The power supply converts the AC voltage and provides a 24 DC volts to the Router.
The Mach3 is powered using LM2596, which reduces the voltage to 5 volts.
Motors drivers for X Y and Z axis are connected with Mach3 from pins P2-7 respec-
tively.
The enable pin to turn the drivers ON is P14.
Relay is attached with Mach3 to control the spindle as an ON and OFF switch.
An emergency switch is connected to Pin 10.
And an external button is also connected to turn the Router ON and OFF.

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 Experimental Setup

Figure 4.10: Control panel of CNC Router

4.11 Mechanical Setup of CNC Router

Figure 4.11: Testing of CNC Router

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 Chapter 5
Results and Discussion
5.1 Results:
Finalizing all the mechanical parameters of CNC Router on software, physical design
was implemented according to the CAD design, which later on was furbished for further
improvements.
Applying ball screws on linear rails increased the movement speed of all 3-axis. X and
Y axis accuracy movement is increase upto 98% and Z axis accuracy is improved upto
96%.

Figure 5.1: Initial design (Left) and Finalized design (Right) of CNC Router

5.1.1 Testing on wood

The first testing of CNC Router was carried out on a wood workpiece to observe the
results, as wood is easy and safe to cut and carve in first trail. The G-code took a total
of 47 minutes to execute the design of 10x10 cm.

Figure 5.2: 1st testing on wood workpiece

 Results and Discussion

5.1.2 Testing on marble without water

Router was run on marble without using water as coolant to check the results that
whether marble piece can be carved smoothly or not or how much amount of water
would be required. Without water, the marble work piece started breaking into small
bits and resulted in a rough finishing of design as shown below.

Figure 5.3: 2nd testing on marble workpiece

5.1.3 Testing on marble with water

For cnc to operate on marble it axis movements speed has to be decrease because due
to the hard surface of marble. Applying water on marble reduces heat due to friction
and also carries away the residue of marble. Water also adds smoothness to design with
smooth finishing of work piece.

Figure 5.4: Final testing on marble workpiece

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 3-AXIS CNC MARBLE CUTTING AND CARVING MACHINE

5.1.4 Accuracy of CNC Router

For the accuracy of router, a series of test were conducted to check the error in move-
ment of all 3-axis for marble cutting and carving. Listed below are the result of tests
conducted to check the accuracy of CNC Router movement compared with measure-
ments of Vernier caliper.

Figure 5.5: Measurements taken from different tests

Results show that the maximum displacement error along x-axis is 0.75mm, Y axis
is 0.81 mm and along Z axis is 0.7mm.

65
 Results and Discussion

5.2 Discussion:
During the construction of the CNC we faced a lot of challenges. Firstly, the compo-
nents were not easily available due to global pandemic, and which caused a great delay
in project timeline.

The second issue we came across was getting the right size of material cut for the Router
according the CAD model designed. As many labors in Pakistan did n’t have much
knowledge CNC Routers specially for marble cutting an carving therefore we somehow
managed to change some dimensions of our CAD Model to overcome this problem.

Thirdly, during the wiring of the motors we came to know that the driver TB6600 we
were using, supplied less power to the stepper motors therefore we changed it with Mi-
crostep DM542 to supply maximum power to the actuators.

Fourthly, for the spindle of the router we faced major problem.As our objective was
to make an affordable router but the spindles available for marble cutting and carving
at international market was very expensive, nearly of Rs 70,000 therefore we preferred
to use DC motor of 28V as a good alternative.

After the fabrication of all 3-axis and spindle we changed open base of the router
into a water collecting tub.Water being used as a coolant is very dangerous for the CNC
therefore for the proper safety a water tub is added on the base of router for collection
of used water, with a drainage hole to drain all water safely.

Another issue we faced during the application of water pump for water supply. 1st
pump we applied got damaged because of high current as our machine works on 3A
current but pump we are using is small for less water wastage therefore, it got damaged.
To overcome this problem we attached water pump with an external source.

Lastly, as mentioned earlier due to COVID-19 sensors for auto-calibration were not
available so to automate the tool positioning of the router we have defined the offsets in
Mach3 software.

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 Chapter 6
Conclusion and Recommendations
6.1 Conclusion
The compilation and study of our body of research and the fabrication of the CNC ma-
chine was accomplished over a period of 15 months. During that time, we researched
things such as marble industries, actuator modeling, and CNC design, and engaged in
mathematical and simulated modeling of the prototype, after which it was manufactured
within safety factors and tested for performance. The prototype was made using easy-
to-replace materials and methods, to allow easy repairs and modifications.

We draw the following conclusions for our work:

• The aluminum bed holding a carbon-steel chassis for axis screw rods is within safe
limits for use, but nonetheless has a “rough” feel.
• The stepper motors used for axial motion yield a design accuracy tolerance of about 5
micrometers.
• The spindle motor can have its tool replaced for different ones for various other oper-
ations.
• A water pump has been attached to remove marble waste.
• All of the machine’s operations can be controlled by a central PC, either automatically
via G-Code, or manually via the provided interface.

6.2 Recommendations for future work

This machine is primarily designed to be used by small-scale marble industries, with
simple and modular parts and an easy-to-use interface. A few things that can be im-
proved in further prototypes, such as:
• The physical design of the model can be renovated, with a more balanced bed and
better support struts.
• Redesign and remodel to optimize operation, reduce weight, and make the physical
model better.
• Look at different materials to replace machine components, to reduce cost and weight
and improve strength.
• Conduct market research for viability and finding useful functionalities to add for the
end-user.
 REFERENCES

References
[1] Information about CNC routers available at https://www.slideshare.net/

[2] Canadian manufaturers of CNC routers https://multicam.ca/

[3] Introduction of CNC routers can be studied at https://edutechwiki.unige.ch/

en/CNC_router

[4] Low cost 3-axis CNC routwr using 8 bit microcontroller based embedded system
using c-language:
https://www.researchgate.net/publication/50194247_Design_and_
Implementation_of_a_Three_Dimensional_CNC_Machine

[5] CNC router for small scale industry using ATMEGA328P AND NEMA 17 stepper
motor for wood carving and engraving:
https://www.ripublication.com/ijaer17/ijaerv12n17_34.pdf

[6] Enriching creative engineering products as high quality and competitive with marble
and stone materials analysis:
http://www.ijirae.com/volumes/Vol6/iss01/04.JAAE10088.pdf

[7] Study analysis of various marble cutters used in stone and marble industry:
https://www.researchgate.net/publication/321236872_Influence_of_
the_physico-mechanical_and_mineral_properties_of_various_marble_
on_diamond_tool_wear

[8] ISO standards for CNC routers https://www.iso.org/obp/ui/#iso:std:iso:

14649:-121:ed-1:v1:en

[9] Stepper motor working explained in https://www.youtube.com/watch?v=

eyqwLiowZiU

[10] G Codes for different shapes and designs available at https://www.intuwiz.

com

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 3-AXIS CNC MARBLE CUTTING AND CARVING MACHINE

Appendix

G Code for rectangle

G21 (Units in millimeters)
G90 (Absolute programming)
G64 (Default cutting)
G17 (XY plane)
G40 (Cancel radius comp.)
G49 (Cancel length comp.)
G0 Z-2
M3 M8
G00 Z0.5 F70
G00 X-14 Y-11.5 F70
G01 Z-1 F50
G01 X-14 Y11.5 F50
G01 X-14 Y-11.5
G00 Z0.5 F70
G1 Z -3
M4 M2 (Program end)

G Code for circle:

G21 (Units in millimeters)
G90 (Absolute programming)
G64 (Default cutting)
G G40 (Cancel radius comp.)
G49 (Cancel length comp.)
M3 M8
G0 Z-2
G00 Z0.5 F70
G00 X-8.5 Y0 F70
G01 Z0.5 F50
G02 I8.5
G00 Z0.5 F70
G1 Z-2
G00 X0 Y0 F70
M4 M2 (Program end) [10]

69