2018_Design, Development and Structure Analysis of Three Axis Benchtop Milling Machine
| Format: | General Document |
|---|
| _version_ | 1860798026190159872 |
|---|---|
| building | INTELEK Repository |
| collection | Online Access |
| collectionurl | https://intelek.unisza.edu.my/intelek/pages/search.php?search=!collection3 |
| copyright | Copyright©PWB2025 |
| country | Malaysia |
| date | 2018-06-25 |
| format | General Document |
| id | 15537 |
| institution | UniSZA |
| originalfilename | 15537_e47bc174ab85350.pdf |
| person | Zammeri Abd Rahman |
| recordtype | oai_dc |
| resourceurl | https://intelek.unisza.edu.my/intelek/pages/view.php?ref=15537 |
| sourcemedia | Server storage Scanned document |
| spelling | 15537 https://intelek.unisza.edu.my/intelek/pages/view.php?ref=15537 https://intelek.unisza.edu.my/intelek/pages/search.php?search=!collection3 General Document Malaysia Library Staff (Top Management) Library Staff (Management) Library Staff (Support) Terengganu Faculty of Innovative Design & Technology English application/pdf 1.5 266 Mechanical Engineering Server storage Scanned document Universiti Sultan Zainal Abidin UniSZA Private Access Universiti Sultan Zainal Abidin SAMBox 2.3.4; modified using iTextSharp™ 5.5.10 ©2000-2016 iText Group NV (AGPL-version) 2018-06-25 15537_e47bc174ab85350.pdf Machine design Milling machinery Structure Analysis 2018_Design, Development and Structure Analysis of Three Axis Benchtop Milling Machine Copyright©PWB2025 The key factor in improving student learning, especially in manufacturing courses is by involving students with the hands-on laboratory experience. Unfortunately, the high cost of commercial CNC machines relatively constraints the number of machines that are accessible for students. In fact, milling machines are expensive and usually come with a relatively high cost of preventive maintenance contracts. Corrective maintenance in case of machine breakdown is a time-consuming process to get the machine back ready on the track. The objective of the research is to design, fabricate, analyse and test a three-axis benchtop CNC milling machine. This machine can use in all Institutions of Higher Learning (IHL) or school that offers the technical or manufacturing courses. Two open frame machine structures were proposed and the conceptual machine structure was initially developed based on application of stress constraint with a desired frequency. The final machine structure was validated with the Finite Element Analysis (FEA). Selected component was used to either reduce costs or improve performance. Therefore, many functional requirements selected based on the capabilities of the similarly sized milling machines that were reviewed in the market research and benchmarking analysis. The machine built up within the platform size of 680 mm (length) × 670 mm (width) × 660 mm (height) and 13000 RPM maximum spindle speed. The results shown that the machine was capable to perform machining operation with the maximum cutting speed of 1650 RPM at an accuracy of 0.1 mm. In terms of machining accuracy and reliability, performing a structural modal analysis is conducted to understand the effects of loads on the physical structures of components. The result of the dynamic analysis was validated using the impact hammer test and the result shown that the average percentage error of the natural frequency is 0.04 %. New computational image analysis technique was developed for measuring the circularity and straightness of sample UHMW-PE. The accepted percentage error result of circular and straightness test reading is 0.88 % and 2 % below the derived requirements laid down. The low cost was achieved with the used the features of standard PC interfaces with Open source Arctsoft Mach3 CNC Controller as a main software with the aid of G-Codes to assign the movement of the axes. Also supported by the use of inexpensive off-the-shelf hardware components that can reduce the maintenance costs. The total cost of producing this milling machine is around RM12, 000.00. Zammeri Abd Rahman Dissertations, Academic Development Design Thesis |
| spellingShingle | 2018_Design, Development and Structure Analysis of Three Axis Benchtop Milling Machine |
| state | Terengganu |
| subject | Mechanical Engineering Machine design Milling machinery Dissertations, Academic |
| summary | The key factor in improving student learning, especially in manufacturing courses is by involving students with the hands-on laboratory experience. Unfortunately, the high cost of commercial CNC machines relatively constraints the number of machines that are accessible for students. In fact, milling machines are expensive and usually come with a relatively high cost of preventive maintenance contracts. Corrective maintenance in case of machine breakdown is a time-consuming process to get the machine back ready on the track. The objective of the research is to design, fabricate, analyse and test a three-axis benchtop CNC milling machine. This machine can use in all Institutions of Higher Learning (IHL) or school that offers the technical or manufacturing courses. Two open frame machine structures were proposed and the conceptual machine structure was initially developed based on application of stress constraint with a desired frequency. The final machine structure was validated with the Finite Element Analysis (FEA). Selected component was used to either reduce costs or improve performance. Therefore, many functional requirements selected based on the capabilities of the similarly sized milling machines that were reviewed in the market research and benchmarking analysis. The machine built up within the platform size of 680 mm (length) × 670 mm (width) × 660 mm (height) and 13000 RPM maximum spindle speed. The results shown that the machine was capable to perform machining operation with the maximum cutting speed of 1650 RPM at an accuracy of 0.1 mm. In terms of machining accuracy and reliability, performing a structural modal analysis is conducted to understand the effects of loads on the physical structures of components. The result of the dynamic analysis was validated using the impact hammer test and the result shown that the average percentage error of the natural frequency is 0.04 %. New computational image analysis technique was developed for measuring the circularity and straightness of sample UHMW-PE. The accepted percentage error result of circular and straightness test reading is 0.88 % and 2 % below the derived requirements laid down. The low cost was achieved with the used the features of standard PC interfaces with Open source Arctsoft Mach3 CNC Controller as a main software with the aid of G-Codes to assign the movement of the axes. Also supported by the use of inexpensive off-the-shelf hardware components that can reduce the maintenance costs. The total cost of producing this milling machine is around RM12, 000.00. |
| title | 2018_Design, Development and Structure Analysis of Three Axis Benchtop Milling Machine |
| title_full | 2018_Design, Development and Structure Analysis of Three Axis Benchtop Milling Machine |
| title_fullStr | 2018_Design, Development and Structure Analysis of Three Axis Benchtop Milling Machine |
| title_full_unstemmed | 2018_Design, Development and Structure Analysis of Three Axis Benchtop Milling Machine |
| title_short | 2018_Design, Development and Structure Analysis of Three Axis Benchtop Milling Machine |
| title_sort | 2018_design, development and structure analysis of three axis benchtop milling machine |