(Đồ án hcmute) compose exercises and operation materials on the 5 axis cnc milling machine for teaching cad cam cnc subject

MINISTRY OF EDUCATION AND TRAINING HCM CITY
UNIVERSITY OF TECHNOLOGY AND EDUCATION
FACULTY OF MECHANICAL ENGINEERING

GRADUATION THESIS
MACHINERY MANUFACTURING TECHNOLOGY

COMPOSE EXERCISES AND OPERATION
MATERIALS ON THE 5-AXIS CNC MILLING MACHINE
FOR TEACHING CAD/CAM - CNC SUBJECT

Advisor: M.E DUONG THI VAN ANH
Students: TRUONG XUAN THAI
Student’s ID: 13143312
Students: LE MINH TAI
Student’s ID: 13143292

SKL 0 0 4 8 6 7

Ho Chi Minh City, July 2017

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MINISTRY OF EDUCATION AND TRAINING
HCM CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION
FACULTY OF MECHANICAL ENGINEERING

GRADUATION THESIS
COMPOSE EXERCISES ON THE 5-AXIS CNC
MILLING MACHINE FOR TEACHING

CAD/CAM-CNC SUBJECT

Advisor: M.E DUONG THI VAN ANH
Students: TRUONG XUAN THAI
LE MINH TAI

Ho Chi Minh City, July 2017

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HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION

FACULTY OF MECHANICAL ENGINEERING

CAPSTONE PROJECT EVALUATION FORM
(FOR REVIEWER USE ONLY)

Title of thesis: Compose exercises on the 5-axis CNC machine for teaching
CAD/CAM-CNC subject
Major: MACHINERY MANUFACTURING TECHNOLOGY.
Student’ s name: Truong Xuan Thai

Student’s ID: 13143312

Student’ s name: Le Minh Tai

Student’s ID: 13143292

Advisor: Duong Thi Van Anh

Academic Position:
Engineering.

Master

of

Name of Institute: MACHINERY MANUFACTURING TECHNOLOGY.

COMMENTS
1. COMMENTS ON ATTITUDE AND BEHAVIOR OF STUDENTS
.......................................................................................................................................................................
.......................................................................................................................................................................
.......................................................................................................................................................................
.......................................................................................................................................................................

2. COMMENTS ON RESULTS OF CAPSTONE PROJECT
2.1. Structure of the capstone project
.......................................................................................................................................................................
.......................................................................................................................................................................
.......................................................................................................................................................................
.......................................................................................................................................................................

2.2. Main contents
.......................................................................................................................................................................
.......................................................................................................................................................................
.......................................................................................................................................................................
.......................................................................................................................................................................

2.3. Results of capstone project
.......................................................................................................................................................................

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.......................................................................................................................................................................
.......................................................................................................................................................................
.......................................................................................................................................................................

2.4. Capstone strengths and weaknesses
.......................................................................................................................................................................
.......................................................................................................................................................................
.......................................................................................................................................................................
.......................................................................................................................................................................

3. EVALUATION
No.
1.

2.

MAX
POINT

CONTENT
Structure of the capstone project

30

Student follows exactly the format for capstone project given
by FME

10

The motivation of the project is clearly provided in the thesis

10

The NEED of project is clearly showed in the thesis

10

Main contents (demonstration that students have ability to):

50

Apply knowledge of math, engineering, and science

5

Analyze and interpret data

10

Design and manufacturing the system, component or process
to meet needs

15

Improvement and development in future

15

Use the software and technical tool to solve the problem

5

3.

Real-life applications of capstone project

10

4.

Products of capstone project

10

Total

100

5. CONCLUSIONS
 Accept
 Reject
HCMC, 15/7/2017:
Advisor
(Signature and Name)

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ACHIEVED
POINT


HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION
FACULTY OF MECHANICAL ENGINEERING
CAPSTONE PROJECT EVALUATION FORM
(FOR REVIEWER USE ONLY)

Title of thesis: Compose exercises on the 5-axis CNC machine for teaching
CAD/CAM-CNC subject
Major: MACHINERY MANUFACTURING TECHNOLOGY.
Student’ s name: Truong Xuan Thai

Student’s ID: 13143312

Student’ s name: Le Minh Tai

Student’s ID: 13143292

Reviewer: Hoang Trung Kien

Academic Position: Doctor of
Philosophy

Name of Institute: MACHINERY MANUFACTURING TECHNOLOGY.

COMMENTS
1. Structure of the capstone project
.......................................................................................................................................................................
.......................................................................................................................................................................
.......................................................................................................................................................................

2. Main contents
.......................................................................................................................................................................
.......................................................................................................................................................................
.......................................................................................................................................................................
.......................................................................................................................................................................

3. Results of capstone project
.......................................................................................................................................................................
.......................................................................................................................................................................
.......................................................................................................................................................................
.......................................................................................................................................................................

4. Capstone strengths and weaknesses
.......................................................................................................................................................................
.......................................................................................................................................................................
.......................................................................................................................................................................
.......................................................................................................................................................................

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5. Questions and Suggestions
.......................................................................................................................................................................
.......................................................................................................................................................................

.......................................................................................................................................................................
.......................................................................................................................................................................
.......................................................................................................................................................................
.......................................................................................................................................................................
.......................................................................................................................................................................

6. EVALUATION
No.
1.

2.

MAX
POINT

CONTENT
Structure of the capstone project

30

Student follows exactly the format for capstone project given
by FME

10

The motivation of the project is clearly provided in the thesis

10

The NEED of project is clearly showed in the thesis

10

Main contents (demonstration that students have ability to):

50

Apply knowledge of math, engineering, and science

5

Analyze and interpret data

10

Design and manufacturing the system, component or process
to meet needs

15

Improvement and development in future

15

Use the software and technical tool to solve the problem

5

3.

Real-life applications of capstone project

10

4.

Products of capstone project

10

Total

100

7. CONCLUSIONS
 Accept
 Reject
HCMC, 15/07/2017
REVIEWER
(Signature and Name)

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ACHIEVED
POINT


COMMITMENT
Project name : Compose exercises on the 5-axis CNC machine for teaching
CAD/CAM-CNC subject

Advisor: M.E Duong Thi Van Anh
Student’s name : Truong Xuan Thai
Student’s ID number : 13143312.
Student’s name : Le Minh Tai
Student’s ID number : 13143292.
Address: Thu Duc District, Ho Chi Minh City
Contact number: 01207.07.02.07
Email:
Commitment: "We commitment that this good essay is the work we study and make.
We do not copy or retrieve any source of personal or corporate material without
specific source. If there is any mistake we take full responsibility. "
TP. Ho Chi Minh City, June 19, 2017
Confirmation of student:

Truong Xuan Thai

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Le Minh Tai


ACKNOWLEDGEMENT
With each student of Mechanical Engineering, graduation project is important. It
could help them to improve, complete and know more about major knowledge. There
for, we effectuated the project “Compose exercises on the 5-axis CNC machine for
teaching CAD/CAM-CNC subject.” for 4 months. After finishing this project, we will
know more to accomplish and meet requirements of mechanical engineer.
Firstly, we would like to say thanks Faculty of Mechanical Engineering for
assigning this project for us. This is challenge for us to study, ameliorate knowledge
about mechanical.

Secondly, we sincere thanks M.E Duong Thi Van Anh for supporting. She
teaches us how to create G-code, load in CNC milling machine and operate it to
processing components. She provides general CNC knowledge, which help us to do
this project easier.
Nextly, we extend our thanks to M.E Dang Minh Phung. He is always beside us
throughout processing this project. With his provision and support about mechanical,
we could make this project better.
Lastly, we want to send deeply thanks to teachers in Ho Chi Minh city
University of Technology and Education, who has been teaching, communicating
useful knowledge for us. That is the basic foundation for our career in the future.
Sincerely thanks.
Ho Chi Minh city, July 15th – 2017
Students perform
Le Minh Tai
Truong Xuan Thai

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ABSTRACTS
Compose exercises on the 5-axis CNC machine for teaching CAD/CAM-CNC
subject
When technology and science are more and more development, CNC field create
many tools, machines, equipment in responding to manufacturing and assembling.
Many complex texture components are manufactured. Therefore, components are
processed in 5-axis CNC milling machine, which are necessary. This is reason why
this project is researched.
With project assignments, we have to perform processing some 3D, 4D and 5D
components in 5-axis CNC milling machine to create model components and
compose exercises for CAD/CAM/CNC subject.

To respond project schedule, we had to study in documents about mechanic and
CNC basic, which we were received from our lecturers. Addition to learning
knowledge in Internet, books… we researched about 5-axis CNC milling machine
current design. At the same time, we learned how to operate and process in this
machine. From that, we improved necessary parts, which couldn’t run 5 axis. When
completed mechanic, we started to program G-code and load in CNC machine, ran
simulation. If it had stability, we manufactured from workpieces to components.
After completing this project, we will have knowledge about designing machine,
necessary skills about CNC machine such as operation, programming 5-axis G-code.
We know how to improve a machine tools.
However, the project has some limitations such as change tools automatically,
machine spindle’s power is low, working area is narrow … So that, we hope the
project to develop better by improving this disadvantages and to help the people who
is learning, researching about 4,5-axis machine as well as how to processing 4D, 5D
model.

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Table of Contents
Chapter 1: OVERVIEW ................................................................................................................. 1

1.1 The old version of the CNC machine ..................................................... 1
1.2 The necessity of this project .................................................................... 2
1.3 Scientific and practical significance ................................................................... 2
1.4 Researching object of the project ........................................................... 2
1.5 Researching object and scope. ................................................................ 3
1.6 Researching methods. .............................................................................. 3
1.6.1 Methodological basis. ...................................................................................................... 3
1.6.2 Researching specific methods. ......................................................................................... 3

1.7

Technical and practical significance. ...................................................... 3

Chapter 2: THEORATICAL BASIC. ............................................................................................. 3

2.1 General information about CNC machine. ................................................ 4
2.2 General configuration about CNC machine. ............................................. 4
2.3 Types of control systems in CNC machine. ................................................ 6
Chapter 3: GENERAL INTRODUCTION 5 AXIS CNC MILLING MACHINE IN THE
BEGINNING ..................................................................................................................................... 8

3. 1 Some pictures of the vailable 5-axis CNC Milling machine. ................... 8
3.2 The available mechanism 5-axis CNC milling Machine ........................... 9
3.2.1. The limited itinerary of the axes: .................................................................................. 9

3.3 The Mach3 Mill controling software: ....................................................... 10
3.3.1 Setting Mach3 Mill software parameters. .................................................................... 10
3.3.2 Conducting Mach3 Mill software. ............................................................................... 16
Chapter 4: THE 5-AXIS CNC MILLING MACHINE OPERATION AND COMPOSE
EXERCISES ON THE 5-AXIS CNC MACHINE. ...................................................................... 28

4.1 The 5-axis CNC milling machine operation. ............................................ 28
4.1.1 Introduce about 5-axis CNC milling machine. ............................................................. 28
4.1.2 The basic operations on 5 axis CNC milling machine. ................................................ 29
4.1.3 Operation and Determination about workpiece reference in 5-axis CNC milling machine
............................................................................................................................................... 31
4.1.4 Load G-code, edit and check errors. ............................................................................ 34
4.1.5 Processing .................................................................................................................... 35

4.2 Compose exercises on the 5-axis CNC milling machine. ........................ 36
4.2.1 Programming process by Creo parametric 3.0 ............................................................. 36
4.2.3 Processing simulation................................................................................................... 42
4.2.4 Exporting NC File. ....................................................................................................... 44
4.2.5 Compose exercises on the 5-axis CNC milling machine. ............................................ 45

Chapter 5: CONCLUSION AND RECOMMENDATIONS ........................ 90
5.1 Solution. ....................................................................................................... 90

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List of abbreviations.
AC: Alternating Current
APT: Advanced Power Technology
CAD: Computer Aided Desgin
CAM: Computer Aided Manufacturing
CIM: Computer Intergraded Manufacturing
CNC: Computeized Numerical Control
DC: Direct Current
DNC: Directe Numerical Control
ID: Inside Diameter
LPT: Line Printer Terminal
MDI: Manual Data Input
NC: Numerical Control
PC: Personal Computer

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Table of Figures.
Figure 1.1. 3-axis CNC milling machine ............................................................................................ 1
Figure 1.2. 4-axis milling machine

Figure 1.3. CAD/CAM-CNC LAB ........................................ 1

Figure 1.4. 5-axis CNC milling machine ............................................................................................ 2
Figure 2.1 CNC machine’s general. .................................................................................................... 4
Figure 2.2: Coordinate system of CNC machine. ............................................................................... 5
Figure 2.3 Right-hand rule. ............................................. 5Error! Thẻ đánh dấu không được xác định.
Figure 2.4 M, W, R point of machine. ................................................................................................ 6
Figure 2.5 P point of program ............................................................................................................. 6
Figure 2.6 Benchmarking of set tools T and point set tools N. ........................................................... 6
Figure 2.7 Open control system. ......................................................................................................... 7
Figure 2.8 Close control system. ......................................................................................................... 7
Figure 3.1: The Available 5-axis CNC milling Machine. ................................................................... 8
Figure3.2 The hardware Available 5-axis CNC milling Machine. ..................................................... 9
Figure 3.3. The background of Mach3 Mill software. ...................................................................... 10
Figure 3.4. Units in the software. ...................................................................................................... 10
Figure 3.6. Setting the Pins Motor control. ....................................................................................... 11
Figure 3.7. Setting cruise switches .................................................................................................... 12
Figure 3.8 Setting input signal. ......................................................................................................... 12
Figure 3.9. Configuring X Motor Parameters. .................................................................................. 13
Figure 3.10 Configuring Y-axis Parameters ..................................................................................... 13
Figure 3.11. Configuring Z-axis Parameters ..................................................................................... 14
Figure 3.12. Configuring Z-axis Parameters ..................................................................................... 15
Figure 3.13. Configuting C-axis Parameters ..................................................................................... 15
Figure 3.14. The main interface of Mach3 controller. ...................................................................... 17
Figure 3.15. Location coordinates of the axes ................................................................................. 17

Figure 3.16. The program control group ........................................................................................... 18
Figure 3.17. Tool Information ........................................................................................................... 19
Figure 3.19. Spindle speed................................................................................................................. 20

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Figure 3.20. MDI page interface ....................................................................................................... 20
Figure 3.21. Interface of Tool Path page. .......................................................................................... 21
Figure 3.22. Interface og offsets page. .............................................................................................. 21
Figure3.23. Interface of settings page. ................................................................................................ 22
Figure 3.24. The Interface of Diagnostics page .................................................................................. 22
Figure 3.25. Dialog box of Using Jog mode and MPG (Handle) .......................................................... 23
Figure 3.26. Dialog box allow to set LPT pins. ................................................................................. 24
Figure 3.27. Functional diagram for each pin of printer port (LPT) ................................................. 24
Figure 3.28. Tab for adjusting the number of encoder pulse to move. ............................................ 26
Figue 3.29. The Board allow to set the keyboard shortcut to move to the axes. ............................... 26
Figure 3.30. The Board allow to set limit cruise by software. .......................................................... 27
Figure 4.1: The 5-axis CNC milling machine Panel. ........................................................................ 28
Figure 4.2: The 5-axis CNC milling machine button ........................................................................ 28
Figure 4.3 Turn on CNC machine ..................................................................................................... 29
Figure 4.4 Open Mach3 Mill soflware. ............................................................................................. 29
Figure 4.5 Reference all home. ......................................................................................................... 30
Figure 4.6 Close Mach3 Mill software. ............................................................................................ 30
Figure 4.7 Power off CNC control. ................................................................................................... 30
Figure 4.8 The axis system show on interface .................................................................................. 31
Figure 4.9 Workpiece reference in CNC machine. ........................................................................... 31
Figure 4.10 Position enter G- code. .................................................................................................. 32
Figure 4.11 Position about zero X and enter X scope. ...................................................................... 32
Figure 4.12 Zero Z position. ............................................................................................................. 33

Figure 4.13 MDI enter position. ........................................................................................................ 33
Figure 4.14 Reset button. .................................................................................................................. 33
Figure 4.15 Load G-code and choose G-code file. ........................................................................... 34
Figure 4.16 Edit G-code button. ........................................................................................................ 34
Figure 4.17 Running tool display. ..................................................................................................... 35
Figure 4.18 Feed Rate Adjustment.................................................................................................... 35

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Figure 4.19 Turn on/off Single Block mode. .................................................................................... 35
Figure 4.20 Cycle Start Mode. .......................................................................................................... 36
Figure 4.21 Click Feed Hold. ............................................................................................................ 36
Figure 4.22 Create processing environment. ..................................................................................... 37
Figure 4.23 Assemble a reference model. ......................................................................................... 37
Figure 4.24 Assemble component at default reference ..................................................................... 38
Figure 4.25 Create Workpiece text box. ........................................................................................... 38
Figure 4.26 Create Solid. .................................................................................................................. 39
Figure 4.27 Workpiece is created...................................................................................................... 39
Figure 4.28 Choose Coordinate System ............................................................................................ 40
Figure 4.29 Set Retract plane. ........................................................................................................... 40
Figure 4.30 Edit tool. ........................................................................................................................ 41
Figure 4.31 Choose processing methods in Mill text box. ................................................................ 41
Figure 4.32 Play Path Simulation...................................................................................................... 42
Figure 4.3 Play Path Simulation........................................................................................................ 43
Figure 4.34 3D Vericut Simulation. .................................................................................................. 43
Figure 4.35 3D Vericut Simulation. .................................................................................................. 44
Figure 4.36 Exporting NC File.......................................................................................................... 44
Figure 4.37 Exercise 1 drawing. ....................................................................................................... 45
Figure 4.38 Profile Milling. .............................................................................................................. 46

Figure 4.39 Edit Tools. ..................................................................................................................... 46
Figure 4.40 Standard Orientation view and Front view. ................................................................... 46
Figure 4.41: Cutting optimization parameters................................................................................... 47
Figure 4.42 Standard Orientation view and Front view. ................................................................... 47
Figure 4.43 Turn on CLDT Cut_com mode. ..................................................................................... 48
Figure 4.44 Pocketing. ...................................................................................................................... 48
Figure 4.45 Finishing. ....................................................................................................................... 48
Figure 4.46 Drilling (Standard). ........................................................................................................ 49
Figure 4.47 Reference. ...................................................................................................................... 49

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Figure 4.48 Standard Orientation view and Front view. ................................................................... 50
Figure 4.49 Tool move wrong when cut 2nd hole. ............................................................................. 50
Figure 4.50 PULLOUT_DIST Parameter. ........................................................................................ 50
Figure 4.51 Simulation result and product about exercise 1. ............................................................ 52
Figure 4.52 Exercise 2 drawing. ....................................................................................................... 52
Figure 4.53 Volume rough. ............................................................................................................... 53
Figure 4.54 Volume Mill Simulation. ............................................................................................... 53
Figure 4.55 Cutting Helical. .............................................................................................................. 54
Figure 4.56 Simulation result and product about exercise 2. ............................................................ 56
Figure 4.57 Exercise 3 drawing ........................................................................................................ 56
Figure 4.58 Volume Rough. .............................................................................................................. 57
Figure 4.59 Engraving....................................................................................................................... 57
Figure 4.60 Edit tool. ........................................................................................................................ 58
Figure 4.61 Reference dialog box. .................................................................................................... 58
Figure 4.62 Edit Pluge_feed parameter. ............................................................................................ 59
Figure 4.63 Simulation result and product about exercise 3. ............................................................ 60
Figure 4.64 Exercise 4 drawing. ....................................................................................................... 60

Figure 4.65 Exercise 1 drawing. ....................................................................................................... 62
Figure 4.66 Roughing. ...................................................................................................................... 63
Figure 4.67 Re-Rough. ...................................................................................................................... 63
Figure 4.68 Simulation result and product about exercise 1. ............................................................ 65
Figure 4.69 Set Zero X. ..................................................................................................................... 65
Figure 4.70 Set Zero Y. ..................................................................................................................... 66
Figure 4.71 Set Zero Z. ..................................................................................................................... 66
Figure 4.72 Set Zero A. ..................................................................................................................... 66
Figure 4.73 Exercise 4D drawing...................................................................................................... 67
Figure 4.74 Roughing. .................................................. 67Error! Thẻ đánh dấu không được xác định.
Figure 4.75 Trajectory ....................................................................................................................... 67
Figure 4.76 Edit Post. ........................................................................................................................ 69

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Figure 4.77 choose 4-axis CNC milling machine. ............................................................................ 70
Figure 4.78 Set height tool to 5 – axis movement. ............................................................................ 70
Figure 4.80 Set Zero X. ..................................................................................................................... 72
Figure 4.81 Set Zero Y. ..................................................................................................................... 72
Figure 4.82 Set Zero Z. ..................................................................................................................... 73
Figure 4.83 Set Zero A. ..................................................................................................................... 73
Figure 4.84 Set Zero C. ..................................................................................................................... 73
Figure 4.85 Exercise 1 drawing. ....................................................................................................... 74
Figure 4.86 Volume Rough. .............................................................................................................. 75
Figure 4.87 Cut Line Milling. ........................................................................................................... 75
Figure 4.88 Drilling Standard. .......................................................................................................... 75
Figure 4.89 Edit reference. ................................................................................................................ 76
Figure 4.90 Edit post to export 5 – axis G-code................................................................................ 76
Figure 4.91 Choose 5 – axis CNC milling machine. ......................................................................... 77

Figure 4.92 Set movements tool........................................................................................................ 77
Figure 4.93 Simulation result and product. ....................................................................................... 79
Figure 4.94 Exercise 2 drawing. ....................................................................................................... 80
Figure 4.95 Volume Rough ............................................................................................................... 81
Figure 4.96 Trajectory ....................................................................................................................... 81
Figure 4.97 Engraving....................................................................................................................... 82
Figure 4.98 Declaring the tool .......................................................................................................... 82
Figure 4.99 Reference dialog box. ................................................................................................... 82
Figure 4.100 Simulation result and product. ..................................................................................... 84
Figure 4.101 Exercise 3 drawing. ..................................................................................................... 85
Figure 4.102 Simulation result and product. ..................................................................................... 86
Figure 4.103. Drawing exercise 4, 5-axis processing. ...................................................................... 87
Figure 4.104 Simulation result and product. ..................................................................................... 89

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Table of Tables.
Table 3.1. The adjustment LPT-signal pins table.............................................................................. 25
Table 4.1 Cut_com parameters. ........................................................................................................ 47
Table 4.3 Processing Technology of Exercise 1. .............................................................................. 51
Table 4.4 RAMP_ANGLE table. ...................................................................................................... 54
Table 4.5 Helical parameters table. ................................................................................................... 54
Table 4.6 Processing Technology of Exercise 2. .............................................................................. 55
Table 4.7 Processing Technology of Exercise 3. .............................................................................. 59
Table 4.8 Processing Technology of Exercise 4. .............................................................................. 61
Table 4.9 Processing Technology of Exercise 1. .............................................................................. 64
Table 4.10 Processing Technology of 4D Exercise. ......................................................................... 71
Table 4.11 Processing Technology of Exercise 1. ............................................................................ 78
Table 4.12 Processing Technology of Exercise 2. ............................................................................ 83

Table 4.13. Processing Technology of Exercise 3. ........................................................................... 86
Table 4.14 Processing Technology of Exercise 4. ............................................................................ 88

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Chapter 1: OVERVIEW
1.1 The old version of the CNC machine
In Vietnam as well as in the world many participants to research and improve
CNC machine to use at home and the small factory with low costs. In HCMC
University of Technology and Education, CNC machines were created by students
for studying. They have designed and generated successfully the 3-axis CNC milling
machine. After that it was improved and upgrade to 4-axis machine.

Figure 1.1. 3-axis CNC milling machine
In last semester, the machine was placed at CAD/CAM-CNC LAB and has been
used for teaching basic CAD/CAM-CNC experiment after cheking, testing machine
operation.

Figure 1.2. 4-axis milling machine

Figure 1.3. CAD/CAM-CNC LAB

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1.2 The necessity of this project
Presently, many students of the University were researched and developed

CNC machines, which has been improved and upgraded to 5-axis from 4-axis CNC
milling machine by themselves. Even though the machine was completed, but it is
not ready to operating and manufacturing. Otherwise in Viet Nam as well as
Universities in Viet Nam is not having many textbooks or manuals about
programming, operating and manufacturing on 5-axis CNC milling machine.
Students have many problems while they studying and processing on this machine
and they have not overcome these problems yet.

Figure 1.4. 5-axis CNC milling machine
1.3 Scientific and practical significance
Researching and manufacturing on the CNC milling machine supports students
to have many new solutions, new development directions.
Researching and manufacturing CNC machine require students have to know
general knowledge about mechanics, electronics and software about CNC. This is
opportunities for students to research, study and learn about modern CNC machines.
And then, they can recreate a CNC machine which is suitable abilities with their
demands.
CNC milling machine project helped to knowledge and skills system. When the
project completed, we could use it for teaching or processing some components not
require too high precision.
1.4 Researching object of the project
Having knowledge of structures, principles of operation, transmission,
programming and control this CNC milling machine. Applying knowledge to
research, development and manufacture of CNC milling machines. Programming,
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controlling the CNC machine to produce the product for demand. The machine's

features enough to serve for teaching and researching.
1.5 Researching object and scope.
Researching object.
 5-axis CNC milling machine made by students of HCMC
University of Technology and Education.
 Controlling software: Mach3 mill
 Designing software: Creo parametric 3.0
 Manufacturing software: Creo parametric3.0
 Simulating software: Creo parametric 3.0
Researching scope.
Researching, manufacturing and completing the remaining of 5-axis CNC
milling machine.
Requirements ensure about:
 Machine’s working volume: 400 x 320 x 300 mm
Period: 4 months
1.6 Researching methods.
1.6.1 Methodological basis.
Based on the knowledge about CNC milling machine have been studied, we
checked, studied and discovered the restrictions and solved this problems.
1.6.2 Researching specific methods.
Survey of practices: Learning about the 5- axis CNC milling machine.
Contraction and experimentation model: manufacturing 5- axis CNC milling
machine, checking operation and processing products.
1.7 Technical and practical significance.
Students will have knowledge of automatically programming (programming,
simulation, adjusting and creating NC program)
Manufacturing on the 5-axis CNC milling machine, which was designed and
machined by HCMC University of Technology and Education’s students.
The project meets requirements about:
 Declearing zero points on the 5-axis CNC milling machine.

 Using basic G, M-files to program manufacturing simple components on the
5-axis CNC milling machine.
 Using manufacturing cycles of CAD/CAM software to automatically program.
 Mastery of basic skill and bare minimum of the machine’s principles of
operation.

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Chapter 2: THEORATICAL BASIC.
2.1 General information about CNC machine.
Computer numerical control (CNC) is the automation of machine tools by
means of computers executing pre-programmed sequences of machine control
commands. This is in contrast to machines that are manually controlled by hand
wheels or levers, or mechanically automated by cams alone.
In modern CNC systems, the design of a mechanical part and its manufacturing
program is highly automated. The part's mechanical dimensions are defined
using computer-aided design (CAD) software, and then translated into manufacturing
directives by computer-aided manufacturing (CAM) software. The resulting
directives are transformed (by "post processor" software) into the specific commands
necessary for a particular machine to produce the component, and then loaded into
the CNC machine.
2.2 General configuration about CNC machine.
Control
uAutomatic
Control program
-Keyboard

Machining unit
-Movement
-Velocity

nit

-Handle
Mechanisms control
Handle
-Automation
Automatic Signal

Workpiece

Cutting machine
-Axes
-Error

Monitor

Model

Figure 2.1 CNC machine’s general.
CNC machine has 2 main parts:
a. Control unit includes program control and mechanisms control.
Program control sets of signals to control with encoding alphas, numbers and
other symbols such as plus, minus, dots… This program is written to have
structure as code (similar binary code in computer memory).
Mechanisms control receives from structure reading program and changed
signal to compatible with movements of machine. And then, it checked action by

feedback from sensor. Enclose: reading mechanisms, decryption, measuring
speed mechanisms, signal unit, changing mechanisms, interpolating mechanisms,
amplification mechanisms, memory and sign in – out other devices.
b. Machining unit:
c. Cutting mental machine and other mechanisms used for automation
such as the manipulation, lubrication system, toolholding… It cuts metal to create
components.
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According to machine technology, machining unit is divided speed box,
working table, toolholding, spindle, manipulation… constituted similar as normal
muti-functional machine, however, some things are difference to ensure
processing automatic control more stability, more exactly, higher productivity and
more open ability technology of machine.
Speed box: is usually infinitely transmission, which uses the
electromagnetic clutch to change pace easier.
Toolholding has transmission source is step motor, use lead screw slit to
guide.
Machine bed: stiffness, reasonable structure to change tool automatically,
escape chip...
In CNC machines, can use many controls to ensure one or more parameters
such as cutting force, noise level, vibration, cutting mode…
Coordinate system of CNC machine.

Figure 2.2: Coordinate system of CNC machine.
Three main movement axis of CNC machine is X, Y and Z. Z axis is
perpendicular with X and Y axis according to right-hand rule (Figure 2.3) create

the coordinate system. Z axis often coincides with the main axis. Positive
direction is far from cutting tools width component. Rotating dimension turn the
same as rotating clockwise view from the origin. X axis is chosen as the axis
created maximum reciprocating. Y axis is perpendicular with X and Z axis
according to right-hand rule.

Figure 2.3 Right-hand rule.
Standard coordinate system:
Machine reference zero (M) is processing in digital machine is setting by
program, which presents relationship between tools and components. To ensure
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exactly manufacturing, tools’ movements are compared to machine reference zero
M. M is point which limits area’s machine. It’s regulated by creator. In milling
machine, it is usually point of limitation movement’s machine.
Machine reference point (R) has not changes to M, regulated by creator.

Figure 2.4 M, W, R point of machine.
Workpiece zero point (W) is original coordination of components and can
configure by programmer. With milling components, W is opted in out corner of
border workpiece.
Programmed point (P) is P point of tools.

Figure 2.5 P point of program
Benchmarking of set tools T and point set tools N: T point is used to determine
tool’s coordinate. Usually setting tool in machine, T and N is once.

Figure 2.6 Benchmarking of set tools T and point set tools N.
2.3 Types of control systems in CNC machine.
Open control system: use step motor to move working table. Because of not feedback
work table position, exactly system depend on features of the step motor is used.

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Figure 2.7 Open control system.
Close control system: use DC servo motor. It measures real position and velocity
of machine and compare to desired value by feedback. If signal difference, it will
continue control motor until signal value is equal.

Figure 2.8 Close control system.

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Chapter 3: GENERAL INTRODUCTION 5 AXIS CNC
MILLING MACHINE IN THE BEGINNING
3. 1 Some pictures of the vailable 5-axis CNC Milling machine.

Figure 3.1: The Available 5-axis CNC milling Machine.

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