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Design of low cost compact modular small scale (CMSS)-CNC lathe machine

Article in International Journal of Applied Engineering Research · March 2013

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 Design of Low Cost Compact Modular Small Scale
(CMSS)-CNC Lathe Machine
Roni Permana Saputra and Tinton Dwi Atmaja
Research Centre for Electrical Power and Mechatronics
Indonesian Institute of Sciences (LIPI)
Komplek LIPI, Jl.Cisitu No.21/154D, Bandung 40135, Indonesia.
Tel.+62-22-2503055, Fax:+62-22-2504773.

Abstract

The emerging of micro factories technology has encourages the development of

CNC machine into small scale design. It purposes is to create a smaller machine to
save some space, reduce production cost, and lower energy consumption. Without
reducing its precision level, this research conduct a design of CNC lathe machine
consist of head stock, main spindle, X-Z axis, bed, tool holder, and X-Z motor
actuators. The design was using three jaw chuck holding method and DC brushless
motor as electric actuator for each axis. Additional harmonic gear was used as the
transmission system. The design was provided in a compact design at 329 mm x
483 mm, assembled in modular design consist several of several module, and can
be considered as low cost module with high availability component even in
domestic market. It was calculated that the resolution of this Compact Modular
Small Scale CNC Lathe machine could achieve 55.5 nm. It is believed that this
design would be able to support many applied industries especially those who need
high precision small component with low production cost.

Keywords: CNC Machine, small scale, lathe, compact, modular, low cost

Introduction
Micro factories are one of the popular emerging technologies having a lot
development within this two decade [1-9]. This popularity was because of the
increased demand of mechanical component into a smaller dimension up to micro
or nano scale for many applications such as electronics control, automobile
component, medical component, etc. [9].
Days before, conventional industries on big and small mechanical components
was produced by standard large equipment. This large equipment means larger
space and higher energy consumption [10] emerging an increased production cost.
Japan was one of the first countries to propose the reducing of machining size
proportional to the size of the produced components [1, 9]. This proposal is to
reduce the production cost, save the energy consumption, spare some space, and
keep every resource correspond to the initial size of produced component [9].
Moreover, the concept can facilitate higher precision mechanism and simpler
equipment than conventional machine. Hence, the concept suits for high precision
industry for small component such as micro censor or micro actuator [9]. This
defines the low cost micro mechanical devices for reducing the production cost.

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 For the present decades, many researches has conducted to develop micro
machine for many application even in academicals scale or laboratorial scale [11-
20]. In Yamanaka Article [12], it was described about the using of different
operation and geometric precision for lathe process according to the size of the
produced part. Detailed explanation pointed out that when the size of the machine
changes, the precision will also be altered and concluded that creating one small
component is more advantageous when using one high precision machine [11-12].
In Ojima et al. (2007) [21], graphical computation on the position of the tool is
provided using CCD camera pointing to the end of the tool. This technique allows
position feedback to the control unit and possible the detection of any dimensional
disturbance in the lathe. Further research by Ojima introduced the use of electron
microscope and SEM (scanning electron microscope) to provide greater detail and
higher accuracy. Later of their researches [11] report a positioning errors
correction in the order of 6 micrometers, and depths of cut of the order of 150
microns. McIntosh, Cordell and Johnson [22] also studied tissue engineering to
produce implants with controlled architecture that can satisfy bioactivity demands
and shaping requirements. Yarlagadda, Chandrasekharan and Shyan [11,23] assist
cells attachment and growth in the interaction surface. Dunn et al [24] discussed
the terms of the in vitro interaction and the in vivo bio-distribution in some animal
models to investigate micro implants for drug delivery. Biomedical purpose is one
of the developing segment as for the production of bone-polymer and bone-
ceramic composite implants, as well as the development of special purpose
machines (Quiroga, 2004 [25]; Rodríguez and Rojas, 2004 [26]; Neira, 2005 [27];
Quevedo, Rojas and Sanabria, 2006 [28]). Rojas (2002) [11,29] has reported about
producing designated screw for joining human bone fracture or other medical
application which need advanced fabrication of composite biomaterials. Jackson et
al. (2005) [30] also studying micromachining in order to carefully handle the
surface of microbeams with proper biocompatibility. Jackson et al used 70
micrometers in diameter rotating tool with speeds of up to 360,000 rpm, depths of
cut of 50 to 100 micrometers, feed of 0.3 m/min and cutting speeds of 100 m/min
to generate chips with a lamellar type structure in consistent with the high induced
deformation rates. It’s created an optimal surface texture and increase the speed of
the tool up to 1 million rpm. The whole previous research justify that
micromachining is important to be developed to support many application.
Proposed design in this paper is a Compact Modular Small Scale (CMSS)-CNC
Lathe Machine with two axes and one spindle module with the order of accuracy
up to 2 µm. designated machine would verify machinability of medical
architectural level at 100-300 µm [29].

CNC Lathe System Design

A lathe system is a machine tool that rotates the workpiece against a tool to
produce cylindrical or conical component and can also be used for drilling process
or boring holes in cylindrical parts [31-32]. Computerized numerical control
(CNC) is one method to control the position and velocity of each motor actuator of
machining tool in the lathe based on numerical data from operators. Hence, CNC
lathe is a computerized controlled lathe system. The main parts of CNC lathe i.e.
head stock, main spindle, X-Z axis, bed, tool holder, and X-Z motor actuator.

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Head Stock
Headstock is a part of CNC Lathe machine serves to hold the electric motor and
the transmission. Its powers the spindle and controls the spindle on designated
rotary variety.
Main Spindle
Spindle is the part of lathe machine to hold the workpiece and rotate along with
the workpiece during the lathe process. Angular velocity of spindle rotation was
powered by adjustable electric motor via transmission system. Working piece was
held in several holding ways i.e. three jaws chuck, collets, and four clamps (shown
in figure 1) [31]. In this present design, used model for holding the work piece is
three jaws chuck because its component has a high availability on domestic market,
simple, and easier in centering process.

(a) (b) (c)

Figure 1. Working piece holding types on lathe machine; (a) Three Jaws Chuck;
(b) collets; (c) four clamps

X axis and Z axis platform

Axis platform is CNC lathe component serves as the base of tool holder which
can move on two axes; x axis and z axis. Both axes were moved by the electric
motor on linear trajectory along its respective axis. To achieve the linear
movement along each axis, it is needed to dispatch a motion converter from rotary
motion to linear translation along the working axis. Moreover, a motor driver is
also needed to achieve more precise and more rigid movement. The axes use ball
screw and linear guide to achieve the designated movement. Figure 2 shows the
component of linear guide and ball screw.

(a) (b)

Figure 2. Component for converting motor rotary movement into linear X-Z
axis movement; (a) ball screw; (b) linear guide

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Tool Holder
Tool holder was attached in the X-Z axis platform (carriage) serves as the base
of the cutting tool on this lathe machine. This part is move along with the X-Z axis
platform during the lathe process.
Bed
This part is the supporting part of the CNC-Lathe machine which needs to be
designed to present a solid base to hold the entire machine and also eliminate any
possible interference vibration.
Motor Actuator
On the design process of CMSS-CNC Lathe machine, the movement of X and
Z axis was powered from oriental motor DC motor brushless. The usage of this
motor is because of it favorable feature i.e. [33]:
1) High efficiency because using permanent magnet rotor and have less
secondary losses
2) Reducible rotor inertia and high velocity response.
3) Because of its high efficiency, it is possible to reduce motor size.
4) Ability to fluctuate its velocity for even slight load changes
Beside all of the technical consideration mentioned above, affordable price also
become one of the primary consideration. With all those feature, the price of this
motor was considered cheap compared with other motor. Table 1 shows the
comparison of motor DC brushless, motor stepper, and motor servo at the same
power.

Table 1. Comparison of motor DC brushless, motor stepper, and motor servo

Feature DC Brushless Stepper AC Servo
Power 30 Watt 30 Watt 30 Watt
Speed Control Available Available Available
Position Control N/A Available Available
Feedback Signal Available N/A Available
Prediction Price IDR IDR IDR

Transmission (Harmonic Gear)

Before attached to X and Y axes of CNC Lathe, generated power from motor
actuator was passed through the transmission system. Transmission system serves
to transmit the power, reduce the velocity, increase the torque, and escalate the
movement precision along X-Z axis. Possible transmission types to be used in this
design are worm-gear, gear-pinion, belt-pulley, and harmonic gear. Figure 3 shows
the description of those four transmission type. Harmonic gear transmission type
was chosen for this design because of its advantages i.e. more rigid, big ratio for
compact size, very low backlash, low losses, etc.

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 (a) (b)

(c) (d)

Figure 3. Transmission system types; (a) worm-gear; (b) pinion-gear; (c) belt-
pulley; (d) harmonic gear

CMSS-CNC Lathe Prototyping Result and Discussion

CMSS-CNC Lathe present design was resulted in a technical prototype consist
of head stock, main spindle, x-z axis platform, spindle motor, tool positioning
motor actuator, tool holder, and bed. This CMSS-CNC Lathe design was based on
modular concept to match small scale factories and capable to achieve micro and
nano scale precision. Nano scale precision will be achieved with high rigidity and
low vibration.

Compact Design
Compact design of CMSS-CNC lathe means that its dimension was optimally
designed compatible to the size of the size of the produced work piece. In this
present design, the CMSS-CNC lathe is at the size of A4 paper (329 mm x 483
mm). Detailed specification of the dimension of designed CMSS-CNC lathe
machine was shown in Table 2.

Table 2. Dimension specification of CMSS-CNC Lathe machine

Specification Size Unit
Length 440 mm
Width 230 mm
Height 200 mm
Weight 27 kg
X axis maximum stroke 60 mm
Z axis maximum stroke 60 mm

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Modular Design
Modular design can be described that the whole module can be divided into
several smaller modules which can independently work under different system [34].
This prototype was designed in several separate modules which can be easily
assembled into one module of CMSS-CNC Lathe. furthermore, each separate
module of this CMSS-CNC Lathe can be substituted by another module, can be
powered up, can be scaled up, and can also configured to serve another different
system. Figure 4 shows the exploded view of CMSS-CNC Lathe machine build
upon its composite parts. Figure 5 shows another configuration from another unit
with replacing the headstock spindle unit with mill cutting tool module, and can
also with replacing tool holder module with workpiece holder module. It is proven
that reconfiguration is possible to upgrade this designed CMSS-CNC Lathe into
much more axes. Figure 6 shows the complete technical prototype of the CNC
Lathe machine

Figure 4. Exploded view of the CMSS-CNC Lathe machine system bases on the
compiling unit

Figure 5. Another possible configuration of CMSS-CNC Lathe using modular

design become 3-axis portable milling machine

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 Figure 6. CNC Lathe Machine complete technical prototype

Small Scale Resolution

Resolution calculation on the smallest movement for this CMSS-CNC lathe
design was using equation (1). Table 3 shows the specification on resolutions and
ratio of the CMSS-CNC components.

(1)

where: Rm = Resolution of the machine / machine precision (mm)

MR = Resolution of the motor / motor precision (rad)
TR = Transmission ratio (rad/rad)
CR = Converter ratio (mm/rad)

Table 3. Specification of CMSS-CNC components

Component Type Parameter Specification
DC Brushless Motor Motor Resolution 2π rad /30
Harmonic Gear Transmission Resolution 1/600 rad/rad
Ball Screw Converter Resolution 10 mm / 2π rad

Working resolution of the designed CMSS-CNC Lathe machine can be

obtained by entering the specification data from Table 3 to equation (1):

It is shown that, theoretically, the working resolution of this designed CMSS-CNC

Lathe machine could reach out until 55.5 nm. It is considered that it can be called
nano machining.

Low Cost
The economical aspect analysis shows that the software can be self-developed
and the dominant cost emerged are for the portable PC as the main processing unit
and the hardware. Table 4 shows the price list and the availability of the
component of this CNC lathe machine.

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Table 4. Component price list and availability
Component Price Availability
1 Main Processing Hardware 3.000.000 IDR Available in domestic market
2 Main Processing Software N/A Can be self-developed
3 Secondary Processing Hardware 2.000.000 IDR Available in domestic market
4 Secondary Processing Software N/A Can be self-developed
5 Mechanical Raw Material 5.000.000 IDR Available in domestic market
6 Mechanical Machining Process 5.000.000 IDR Available in domestic market
7 X-Y Actuator 8.000.000 IDR Available in domestic market
8 Spindle Actuator 4.000.000 IDR Available in domestic market
9 Transmission system 8.000.000 IDR Available in domestic market
TOTAL 35.000.000 IDR

Overall, the cost of the whole processing system is approximately 35 million

IDR and the availability is high even in domestic market. This production cost
considered low because it can achieve micro scale accuracy and even nano scale
accuracy. The average cost for CNC lathe machine for micro scale for the other
brand is approximately 30 million and increased to 50 million for nano scale
machine. So, this design can save about 15 to 20 million IDR and can save much
more when it produced in mass production.

Conclusion
This research concludes that the design of CMSS-CNC lathe consist of head
stock, main spindle, X-Z axis, bed, tool holder, and X-Z motor actuators. This
design can provide advantages such as compact design, modular machine with low
production cost, and being able to perform lathe process up to 55.5 nm. This design
can be upgraded into 3-axis portable milling machine or even more axes. The
production cost is considered low because it was approximately 35million IDR and
its component have high availability in domestic market so it won’t need any
additional custom charges. When the resolution has achieved nano scale, further
researches will be needed for reducing any environment interference.

Acknowledgment
The authors would like to thank Indonesia Toray Science Foundation (ITSF)
for the 2011 Research Grant and to Research Centre for Electrical Power and
Mechatronics for the support and the devices on the completion of this portable
CNC research. The Authors would also like to thanks Dian Andriani for the
enormous continual support on international resources. The authors would also like
to acknowledge all parties correspond to this research.

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