Build Your Own CNC Machine

224 Pages·2009·10.26 MB·English

by  Patrick Hood-Daniel, James Floyd Kelly (auth.)

CONTENTS

Build Your Own
CNC Machine

■ ■ ■
Patrick Hood-Daniel
James Floyd Kelly

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(cid:2)(cid:3)(cid:2)CONTENTS
Build Your Own CNC Machine
Copyright © 2009 by Patrick Hood-Daniel and James Floyd Kelly
All rights reserved. No part of this work may be reproduced or transmitted in any form or by any means,
electronic or mechanical, including photocopying, recording, or by any information storage or retrieval
system, without the prior written permission of the copyright owner and the publisher.
ISBN-13 (pbk): 978-1-4302-2489-1
ISBN-13 (electronic): 978-1-4302-2490-7
Printed and bound in the United States of America 9 8 7 6 5 4 3 2 1
Trademarked names may appear in this book. Rather than use a trademark symbol with every
occurrence of a trademarked name, we use the names only in an editorial fashion and to the benefit of
the trademark owner, with no intention of infringement of the trademark.
President and Publisher: Paul Manning
Lead Editors: Jonathan Gennick
Technical Reviewers: Darrell A. Kelly, Jim Burt
Editorial Board: Clay Andres, Steve Anglin, Mark Beckner, Ewan Buckingham, Tony Campbell,
Gary Cornell, Jonathan Gennick, Michelle Lowman, Matthew Moodie, Jeffrey Pepper, Frank
Pohlmann, Ben Renow-Clarke, Dominic Shakeshaft, Matt Wade, Tom Welsh
Coordinating Editor: Kelly Moritz
Copy Editor: Damon Larson
Compositor: Lynn L’Heuruex
Indexer: Ann Rogers/Ron Strauss
Artist: April Milne
Cover Designer: Kurt Krames
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New York, NY 10013. Phone 1-800-SPRINGER, fax [phone], e-mail [email protected],
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any liability to any person or entity with respect to any loss or damage caused or alleged to be caused
directly or indirectly by the information contained in this work.

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■ CONTENTS

Patrick wishes to dedicate this book to his father – “Everyday I attempt to approach
his level of logic and perfection. Rest in peace.”

Jim dedicates this book to his dad – “I’ve learned a lot from you and enjoyed the
company.”
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■ CONTENTS
Contents at a Glance
■About the Authors .................................................................................................................. x
■About the Technical Reviewers ............................................................................................ xi
■Acknowledgments ............................................................................................................... xii
■Introduction .......................................................................................................................... xiii
■Chapter 1: Your CNC Machine ............................................................................................. 1
■Chapter 2: Hardware and Tools .......................................................................................... 5
■Chapter 3: Tips and Advice ............................................................................................... 13
■Chapter 4: Movement Using Rails .................................................................................... 23
■Chapter 5: Joining Methods .............................................................................................. 35
■Chapter 6: The Electronics ................................................................................................ 49
■Chapter 7: X-Axis, Part 1 ................................................................................................... 73
■Chapter 8: X-Axis, Part 2 ................................................................................................... 81
■Chapter 9: X-Axis, Part 3 ................................................................................................... 91
■Chapter 10: Y-Axis, Part 1 ................................................................................................. 99
■Chapter 11: Y-Axis, Part 2 ............................................................................................... 109
■Chapter 12: Y-Axis, Part 3 ............................................................................................... 121
■Chapter 13: Preparing for the Z-Axis ............................................................................. 135
■Chapter 14: Z-Axis, Part 1 ............................................................................................... 149
■Chapter 15: Z-Axis, Part 2 ............................................................................................... 159
■Chapter 16: Z-Axis, Part 3 ............................................................................................... 167
■Chapter 17: Mounting the Electronics ........................................................................... 183
■Chapter 18: Software and Testing .................................................................................. 197
■Chapter 19: Where to Go from Here ............................................................................... 209
■Index .................................................................................................................................. 217

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■ CONTENTS

Contents
■About the Authors .................................................................................................................. x
■About the Technical Reviewers ............................................................................................ xi
■Acknowledgments ............................................................................................................... xii
■Introduction .......................................................................................................................... xiii
■Chapter 1: Your CNC Machine .............................................................................................. 1
What is CNC? .............................................................................................................................. 1
Industrial Uses ................................................................................................................... 2
Personal Uses .................................................................................................................... 2
Your DIY CNC Machine ................................................................................................................ 3
What’s Next? ............................................................................................................................... 4
■Chapter 2: Hardware and Tools ........................................................................................... 5
The Tools .................................................................................................................................... 5
The Electronics Vendors ............................................................................................................ 12
What’s Next? ............................................................................................................................. 12
■Chapter 3: Tips and Advice ................................................................................................ 13
Cut Once ................................................................................................................................... 13
Protect Yourself ......................................................................................................................... 14
Protect Your Lungs .................................................................................................................... 15
Label Parts ................................................................................................................................ 16
MDF Sheets and Sizes ............................................................................................................... 17
Limit Your Cuts .......................................................................................................................... 18
Time Your Cuts .......................................................................................................................... 20
Encouragement ......................................................................................................................... 20
What’s Next? ............................................................................................................................. 21
■Chapter 4: Movement Using Rails .................................................................................... 23
Bearing-Rail Assembly .............................................................................................................. 23
Riding the Rail ........................................................................................................................... 32
Tips and Advice ......................................................................................................................... 33
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What’s Next? ............................................................................................................................. 33
■Chapter 5: Joining Methods ............................................................................................... 35
Two Pieces of MDF ................................................................................................................... 35
Method 1: Cross Dowels ............................................................................................................ 38
Method 2: Bolt, Washer, and Nut ............................................................................................... 43
Which Method Is Best? .............................................................................................................. 44
Building a Jig to Drill ................................................................................................................. 45
What’s Next? ............................................................................................................................. 47
■Chapter 6: The Electronics ................................................................................................. 49
The Required Components ........................................................................................................ 49
Preparing the Stepper Motor Wires ............................................................................................ 53
Preparing the Power Supply ...................................................................................................... 56
Preparing the Breakout Board.................................................................................................... 59
Providing Power to the Stepper Motor Drivers ............................................................................ 62
Wiring Motor Drivers to the Breakout Board ............................................................................... 64
Connecting Power to Motor Drivers ........................................................................................... 65
Connecting Stepper Motors to Motor Drivers ............................................................................. 67
Wiring the Cooling Fan .............................................................................................................. 69
Testing the Electronics .............................................................................................................. 70
What’s Next? ............................................................................................................................. 71
■Chapter 7: X-Axis, Part 1 .................................................................................................... 73
The X-Axis MDF Parts ................................................................................................................ 73
The X-Axis Table ....................................................................................................................... 74
Cutting Rails for Tabletop Sides ................................................................................................. 79
Summary of Work ..................................................................................................................... 80
What’s Next? ............................................................................................................................. 80
■Chapter 8: X-Axis, Part 2 .................................................................................................... 81
Drilling the Table ....................................................................................................................... 81
Drilling Holes for Legs ............................................................................................................... 85
Cutting the Table Ends .............................................................................................................. 86
Summary of Work ..................................................................................................................... 90
Hardware Required ................................................................................................................... 90
What’s Next? ............................................................................................................................. 90
■Chapter 9: X-Axis, Part 3 .................................................................................................... 91
Drilling the Table Ends (Legs) .................................................................................................... 91
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Drilling and Mounting the Rail ................................................................................................... 95
Attaching the Table Legs ........................................................................................................... 96
Cutting the X-Axis Lead Screw .................................................................................................. 97
Summary of Work ..................................................................................................................... 98
Hardware Required ................................................................................................................... 98
What’s Next? ............................................................................................................................. 98
■Chapter 10: Y-Axis, Part 1 .................................................................................................. 99
The Y-Axis MDF Parts ................................................................................................................ 99
Parts Q and R: The Y-Axis Gantry Sides .......................................................................... 100
Building BRAs for Gantry Sides....................................................................................... 105
Summary of Work ................................................................................................................... 108
Hardware Required ................................................................................................................. 108
What’s Next? ........................................................................................................................... 108
■Chapter 11: Y-Axis, Part 2 ................................................................................................ 109
The Y-Axis MDF Parts .............................................................................................................. 109
Attaching BRAs and Gantry Sides ............................................................................................ 110
Part P: The Y-Axis Gantry Bottom Support ............................................................................... 114
Summary of Work ................................................................................................................... 119
Hardware Required ................................................................................................................. 120
What’s Next? ........................................................................................................................... 120
■Chapter 12: Y-Axis, Part 3 ................................................................................................ 121
The Y-Axis MDF Parts .............................................................................................................. 121
The Rail Support ...................................................................................................................... 122
Finishing the Y-Axis Frame ...................................................................................................... 128
Tips on Final Frame Assembly ................................................................................................. 132
Summary of Work ................................................................................................................... 132
Hardware Required ................................................................................................................. 132
What’s Next? ........................................................................................................................... 133
■Chapter 13: Preparing for the Z-Axis ............................................................................. 135
The Y-Axis BRA Supports ........................................................................................................ 135
Cutting and Drilling Parts C and D ........................................................................................... 136
Measuring for the Z-Axis ......................................................................................................... 144
Summary of Work ................................................................................................................... 146
Hardware Required ................................................................................................................. 147
What’s Next? ........................................................................................................................... 147
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■Chapter 14: Z-Axis, Part 1 ................................................................................................ 149
The Z-Axis MDF Parts .............................................................................................................. 149
Part F: The Z-Axis Rail Support ................................................................................................ 150
Parts W and X: The Z-Axis Bearing Supports ........................................................................... 154
Z-Axis Bearing-Rail Assemblies ............................................................................................... 155
Summary of Work ................................................................................................................... 157
Hardware Required ................................................................................................................. 157
What’s Next? ........................................................................................................................... 157
■Chapter 15: Z-Axis, Part 2 ................................................................................................ 159
Preparing to Drill ..................................................................................................................... 159
Drilling Part F: The Z-Axis Rail Support .................................................................................... 159
Drilling Parts W and X: The Z-Axis Bearing Supports ................................................................ 161
Mounting the Z-Axis Bearing-Rail Assemblies .......................................................................... 164
Summary of Work ................................................................................................................... 166
Hardware Required ................................................................................................................. 166
What’s Next? ........................................................................................................................... 166
■Chapter 16: Z-Axis, Part 3 ................................................................................................ 167
Cutting the Z-Axis Rail Support Rails ....................................................................................... 167
Cutting and Drilling Parts M and N ................................................................................. 169
Cutting and Drilling Part V .............................................................................................. 173
Assembling the Z-Axis ............................................................................................................. 174
Attaching the Z-Axis to the Machine ........................................................................................ 176
Summary of Work ................................................................................................................... 181
Hardware Required ................................................................................................................. 181
What’s Next? ........................................................................................................................... 181
■Chapter 17: Mounting the Electronics ............................................................................ 183
Cutting and Drilling the Motor Mounts ..................................................................................... 183
Mounting Your Router .............................................................................................................. 191
Summary of Work ................................................................................................................... 194
Hardware Required ................................................................................................................. 195
What’s Next? ........................................................................................................................... 195
■Chapter 18: Software and Testing ................................................................................... 197
CAD, CAM, and Control Software ............................................................................................. 197
The Mach3 Control Software ................................................................................................... 197
Downloading and Installing Mach3 .......................................................................................... 198
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Configuring Mach3 .................................................................................................................. 200
Ports and Pins ................................................................................................................ 200
Motor Outputs ................................................................................................................ 201
Input Signals .................................................................................................................. 201
Motor Tuning and Setup ................................................................................................. 202
Configuring the Default Motor Units ............................................................................... 203
Testing Your Machine .............................................................................................................. 203
Testing the Router ................................................................................................................... 206
School Starts ........................................................................................................................... 207
What’s Next? ........................................................................................................................... 208
■Chapter 19: Where to Go from Here ................................................................................ 209
Getting Familiar with CAD ........................................................................................................ 209
Getting Familiar with CAM ....................................................................................................... 210
Installing an Emergency Stop .................................................................................................. 210
Adding Limit Switches ............................................................................................................. 213
Adding a Solid State Relay ....................................................................................................... 214
Protecting and Painting Your Machine ..................................................................................... 215
What’s Next? ........................................................................................................................... 215
■Index ................................................................................................................................... 217

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