RETROFITTING OF DENFORD TRIAC

CNC MILLING MACHINE

PROGRESS REPORT

Submitted in partial fulfilment of the requirement for award of the degree of

Bachelor of Technology
(Mechanical Engineering)

UNDER THE GUIDANCE OF:

DR. V. R. KOMMA

SUBMITTED BY:
HARSHVARDHAN SHARMA (REG. NO. 20163047)
DIVYANSH YADAV (REG. NO. 20163090)
B.TECH. VII SEMESTER

MECHANICAL ENGINEERING DEPARTMENT

MOTILAL NEHRU NATIONAL INSTITUTE OF TECHNOLOGY
ALLAHABAD
2019-20 (ODD SEMESTER)

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 CANDIDATE’S DECLARATION

We hereby certify that the work which is being presented in the progress report entitled

“RETROFITTING OF DENFORD TRIAC CNC MILLING MACHINE” in fulfillment of

requirements for the award of degree of Bachelor of Technology in Mechanical Engineering at

MOTILAL NEHRU NATIONAL INSTITUTE OF TECHNOLOGY, ALLAHABAD is an

authentic record of our work carried out during a period from July 2019 to November 2019 under

the supervision of Dr. V. R. Komma. The matter embodied in the report has not been submitted to

any other University / Institute for any purpose.

Signature of the Students

HARSHVARDHAN SHARMA DIVYANSH YADAV

(Reg. No.20163047) (Reg. No.20163090)

This is to certify that the above statement made by the candidates is correct to the best

of my knowledge.

Dr. V. R. KOMMA
Supervisor

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 ACKNOWLEDGEMENTS

The authors are highly grateful to the Director, Motilal Nehru National Institute of technology

(MNNIT), Allahabad for providing this opportunity to carry out the present project work. We

avail this opportunity to extend our hearty indebtedness to our guide Dr. V. R. Komma for his

invaluable guidance, untiring efforts and meticulous attention at all stages during our course of

work. We would also like to convey our deep regards to our project panel members for their

patience, constant motivation and regular monitoring of the work and inputs for which this work

has come to fruition. We express our gratitude to Prof. A. D. Bhatt, Head of the Department

for providing us the necessary facilities in the department.

We cannot forget to mention thanks to lab assistants in CAM Lab for giving their time in

completing the project in spite of their heavy work load. Last but not least, our sincere thanks to

all who have patiently extended all sorts of help for accomplishing this undertaking.

Name of Students
HARSHVARDHAN SHARMA (Reg. No. 20163047)
DIVAYANSH YADAV (Reg. No. 20163090)

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 ABSTRACT

Milling is one of the most widely used machining operations. It allows us to make a variety of part

geometries and is suitable for almost all materials used in the manufacturing process. Therefore,

CNC Milling became very popular with the advent of CNC Machines. One such CNC Milling

machine is the Denford TRIAC CNC milling Machine present in our Computer Aided

Manufacturing (CAM) laboratory. It is originally a Two and a Half milling machine which is

capable of producing part geometries of very close tolerances and with very good repeatability.

However, in the existing state it has a number of limitations which have put it out of function.

We therefore took up the task of restoration of the machine as it provides us with an opportunity

to use our engineering knowledge to save it from being wasted. Retrofitting became the choice of

our project because it would not only refurbish the machine at a minimum cost but also provide a

challenge to make use of every working part of the existing system. We also have the chance to

interface the machine to a PC with Mach3 Software which itself is a major upgrade in the usability

of the machine. In future, this gives a scope of integrating the machine with other machine tools

to make a Flexible Manufacturing System (FMS) as well. Once completed, we would have a user-

friendly machine with appreciably extended service life.

The methodology of our work would be to test every component for faults and implement

necessary repairs and/or replacements. We would begin with study of available resources, perform

repair and fabrication as required with the aid of facilities available to us both inside and outside

the college and target completion of the project by dividing it into a number of short-term

objectives as presented in this report.

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 List of tables

1.1 Mechanical Specifications 11

1.2 Electrical Specifications 11

4.1 Connection between breakout board and 16w ribbon 24

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 List of figures

1.1: Denford TRIAC CNC milling machine 11

1.2 Overview of ATC 13
1.3 Overview of spindle 13
3.1 Flow chart representing retrofitting 16
3.2 Configuration setting window MACH3 18
3.3 Break-out board 19
3.4 Wiring diagram 20
3.5 IRF-520 MOSFET module 21
4.1 Flow diagram of command signal 22
4.2 Connections of Break-out board 23
4.3 Disassembled milling head 25
4.4 Vertical head disassembling 25
4.5 Z axis top view 25
4.6 Guideways after treatment 26
4.7 Z axis lead screw rear view 26
4.8 Guideways and jib strip 27
4.9 Jib strip 27
4.10 Gas welded part 27
4.11 Jib strip adjustment screw 27
4.12 Lubrication pump assembly 28

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 Table of Contents
Chapter 1
1.1 Introduction ................................................................................................................................8
1.2 Denford TRIAC CNC Milling Machine ..................................................................................... 10
1.3 Machine Specifications ................................................................................................................ 11
1.4 Capabilities and Limitations ........................................................................................................ 12

Chapter 2
2.1 Objectives……………………………………………………………………………………14
2.2 Methodology…………………………………………………………………………………15

Chapter 3
3.1 Retrofitting .............................................................................................................................. 16
3.2 Mach3 Software .......................................................................................................................17
3.3 Break-out Board .......................................................................................................................19

Chapter 4
4.1 Work Progress ..........................................................................................................................22
4.2 Completed Objectives ..............................................................................................................29
4.3 Remaining Objectives ..............................................................................................................29

Chapter 5
5.1 References ................................................................................................................................30

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 CHAPTER 1

1.1 Introduction

Milling is a machining operation in which a work part is fed past a rotating cylindrical tool with

multiple cutting edges. The axis of rotation of the cutting tool is perpendicular to the direction of

feed. The cutting tool in milling is called a milling cutter and the cutting edges are called teeth.

The conventional machine tool that performs this operation is a milling machine. Owing to the

variety of shapes possible and its high production rates, milling is one of the most versatile and

widely used machining operations. Milling is an interrupted cutting operation; the teeth of the

milling cutter enter and exit the work during each revolution. This interrupted cutting action

subjects the teeth to a cycle of impact force and thermal shock on every rotation. The tool material

and cutter geometry must be designed to withstand these conditions.

Computer numerical control (CNC) is a method for automating control of machine tools through

the use of software embedded in a microcomputer attached to the tool. It is commonly used in

manufacturing for machining metal and plastic parts. With CNC, each object to be manufactured

gets a custom computer program, usually written in an international standard language called G-

code, stored in and executed by the machine control unit (MCU), a microcomputer attached to the

machine. The program contains the instructions and parameters the machine tool will follow, such

as the feed rate of materials and the positioning and speed of the tool's components. Mills, lathes,

routers, grinders and lasers are common machine tools whose operations can be automated with

CNC. It can also be used to control non-machine tools, such as welding, electronic assembly and

filament-winding machines.

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CNC Milling combines the versatility of milling operation with the convenience of CNC hardware.

CNC Mills can quickly produce parts that would normally need multiple manufacturing steps. The

use of CNC Mill allows operators to take advantage of raw materials and minimize waste through

increased accuracy. The automated fabrication process means that the operator can avoid injury

during an operation. CNC Mills use internal quality assurance detectors to prevent waste of

material when a deficiency is found.

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1.2 DENFORD TRIAC CNC MILLING MACHINE

Triac CNC milling machine is a product of DENFORD where TRIAC stand for three axis motion

(x, y and z). This machine was made in 1987. It utilized the then advances in microprocessor

technology which could be combined with a quick tool changing system and work holding

accessories to provide a powerful and very versatile machine tool. TRIAC’s programming format

is the international standard G and M codes.

Main Features:

• Designed specifically for Education, Training and Prototyping.

• Manufactured to industrial standards.

• Capable of cutting resistant materials, such as wax, plastics, acrylics, copper, aluminium and

steel.

• Totally enclosed high visibility interlocked guard.

• Feed rate and spindle speed override controls.

• CE approved for safety.

• Flexible workholding capabilities.

• Easily upgradeable for inclusion in FMC/FMS/CIM systems.

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 Fig 1.1: DENFORD TRIAC CNC MILLING MACHINE

1.3 Machine Specifications

Mechanical

Working table surface 500x160 mm2

Longitudinal travel 300 mm
Cross travel 180 mm
Head travel 235 mm
Spindle to table 275 mm
Spindle to column 170 mm
Spindle taper R8
Z axis ball screw 16mm dia x 5mm pitch
Y axis ball screw 16mm dia x 5mm pitch
X axis ball screw 16mm dia x 5mm pitch
Max machine length 990 mm
Max machine width 710 mm
Height 980 mm
Weight 240 kg
Mechanical Resolution 0.01 mm
Table 1.1 Mechanical Specifications
Electrical

Variable speed machine 50 Hz/60 Hz – 1 phase 220V

Variable speed spindle motor 0.371 kW 380-240 V 1.3 Amp
Axis stepper motor 200 steps/rev, 3.1 amp 2.9V
Table 1.2 Electrical Specifications

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1.4 Capabilities and Limitations
Capabilities:

• Three axes motor drives (X, Y and Z) enable this CNC Milling Machine to produce

different types of part geometries which may not be feasible by manual methods.

• This machine can reach very high accuracy (up to 0.01 mm) and maintain very close

tolerances in dimension of the part being produced.

• The repeatability of the machining operation allows it to be suitable for medium and long

production runs.

• The feature of an Automatic Tool Changer makes it easier to switch between tools

without any hassle. Thus, total machining time is reduced significantly.

• Pneumatic Spindle and ATC make gripping of tool and machining of workpiece easier.

Limitations in the existing state:

• The Motor Drives require overriding the main contactor to function.

• The inbuilt microcontroller is an outdated type.

• The Pneumatic Systems of Spindle and ATC are not working.

• Pneumatic work holding devices are not setup.

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Fig 1.2: Overview of ATC

Fig 1.3: Overview of Spindle

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 CHAPTER 2

2.1 Objectives

The target of this project from the outset is to completely restore the machine to working condition.

Therefore, we broke down the objective into a number of short-term goals which are as listed

below:

1. Study of Mach3 Software and setting it up on PC.

2. To restore the axes drives.

3. To restore the spindle drive.

4. Interfacing of axes drives and spindle with PC.

5. To repair the Lubricating Pump.

6. To repair the pneumatic tool holding mechanism and ATC.

7. Setup of pneumatic work holding devices.

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2.2 Methodology

In the starting phase of the project, the machine manual was studied to understand the function of

each component which is there in the machine. Then, the electrical connections of the machine

were checked and if any fault was detected, necessary solutions were implemented. Then, the

inbuilt microcontroller was bypassed by the use of a Parallel Port Break-out Board. Thus, the X

and Y axes drives were enabled to receive command signals from a User’s PC running Windows

XP with the use of Mach3 Software. Then, it was found that Z axis was not functioning due to

rusting in the guideways. Then the Z axis drive assembly was disassembled to remove the rust. It

was found that the Locking Mechanism on the Z axis Guide Rod was broken, therefore, repairing

it has been the target of our work in the past week.

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 CHAPTER 3
3.1Retrofitting

Retrofitting refers to the addition of new technology or features to older systems. A CNC retrofit

typically upgrades the CNC, the axes motors and drives, the spindle motor and drives, and a portion

of the associated wiring and related electromechanical components. Unlike rebuilding and

remanufacturing, a CNC retrofit does not include any major repairs to the machine mechanics.

When retrofitting a CNC machine, we add some features which were not a part of the original

product. For example: a new microcontroller and control interface. Retrofitting also gives an

opportunity to replace subsystems that need frequent maintenance with an alternative. Hence, we

end up with an optimized product which: better suits the need of a user and has an increased service

life. If the machine tool is in good shape mechanically, CNC retrofitting is typically the lowest

cost solution to improve the overall performance of an older machine tool.

Existing Machine

Repair and Replace

systems

Retrofit Machine

Fig 3.1: Flowchart representing retrofitting

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3.2 Mach3 Software

It is a software package developed by artSoft Software Incorporated, USA. Mach3 software runs

on a PC and turns it into a very powerful and economical Machine Controller. Mach3 and its

parallel port driver communicate with the machine hardware through one (or optionally two)

parallel (printer) ports. It runs best on Windows XP (alternatively, on a compatible OS with 32-bit

system). It can be integrated with a parallel port driver to communicate with the machine hardware.

Mach3 generates step pulses and direction signals to perform the steps defined by a G code part

program and sends them to the port(s) or motion controller board. To set up the Triac Milling

Machine to use Mach3, the software was installed on a PC and the motor drives were connected

properly with a Break-out Board.

What Mach3 can do?

• Mach3 can control all the three axes drives (x, y and z) of the Triac Milling Machine.

• It sends the step and direction signals needed by the Stepper Motors to move the table (x and

y motion) and the tool head (z motion).

• It can control the limit switches and prevent table overtravel or overcutting.

• It can provide an emergency stop in case of any fault by operating the Emergency Stop Button.

• It also controls the spindle drive and the Automatic Tool Changer (ATC).

• It can also control additional functions like lubricant flow, spindle speed and direction of

rotation, etc.

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Defining Input and Output Signals using Mach3 and Break-out Board:

In the settings panel, we enable and disable required ports and pins of the break- out board. We

also have to specify the respective pin number which will be used for a specific purpose (For

example: Pin number 2 for X axis Step Signal). In our case, we enabled six pins (two each for the

step and direction signals of the three independent axes x, y and z.)

Fig 3.2: Configuration Settings Window of Mach3

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3.3 Break-out Board

Break-out board is an electronic device designed for a flexible interface between CNC machine

and computer system. It is fully compatible with the Mach3 software. It is the bridge between the

machine hardware and the computer. We have used a parallel port break-out board manufactured

by Tiny Controls, New Delhi.

Functions:

• It translates signal between CNC machines and PC signals.

• It isolates the PC motherboard from electrical faults.

• It gives step and direction outputs to stepper motors for the motion of the three axes drives (x,

y and z).

• It can also be used to control the spindle drive.

Fig 3.3: Break-out Board

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 Fig 3.4: Wiring Diagram

Connecting the break-out board:

The break-out board is connected to the PC and receives input from the Mach3 software. The

Emergency Stop (E-Stop) switch and limit switches of each axes drive are also connected to the

break-out board. The output from each of the break-out board pins is sent to the Driver Cards with

a MOSFET in between them.

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Need of a MOSFET:

Metal Oxide Semiconductor Field Effect Transistor (MOSFET) is an electronic device which is

used for switching and amplifying electronic signals like voltage and current. We used the

MOSFET between the Break-out Board and the Driver Cards. It serves the purpose of converting

12V output from the Break-out Board into 5V signals going to the Driver Cards. This is done to

ensure that the Triac PCB does not blow off.

Fig 3.5: IRF 520 MOSFET Module

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 CHAPTER 4
4.1 Work Progress

So far, we have completed the following tasks:

1. Input and Output Signals of the Axis Drives have been rerouted through the Break-out

Board. The following flow diagram depicts how the axis drives receive command signals

in the new setup as compared to the previous setup:

Machine VDU and Keyboard User PC

In-built Controller Break-out Board

Main PCB MOSFET

Axes Driver Cards Axes Driver Cards

To Stepper Motors To Stepper Motors

Fig 4.1: Flow diagram of command signals, (LEFT) Old Setup and (RIGHT) New Setup

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 Fig. 4.2 (a) Fig. 4.2 (b)

Fig. 4.2 (c)

a. Connection between Break-out Board pins and the Axes Driver Cards.

b. Overall Setup.

c. Connection between PC, break-out board and the MOSFETs.

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The connections as mentioned in the Maintenance Manual of the machine were implemented

through the use of a Break-out Board. The following table summarizes the Pin Number and

Function relationship on the TRIAC PCB:

Pin Number (on 16w ribbon) Function Pin Number on Break-out Board

6 X Step 2

7 X Direction 3

15 Y Step 4

14 Y Direction 5

16 Z Step 6

5 Z Direction 7

Table 4.1 Connections between break-out board and 16w ribbon

2. Studied the electrical connections of the main contactor in the manual and found the

requirement of 220V Supply for its working. Thus, we provided a separate 220V Mains

supply to the main contactor.

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 3. The Z axis drive assembly was disassembled.

Fig 4.3: Disassembled Fig 4.4: Vertical head

Milling Head disassembling

Fig 4.5: Z Axis Top view

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4. Guideways were treated with Anti-Rust WD-40 Liquid and then lubricated with oil.

Fig 4.6: Guideways after treatment

with WD40 Spray

5. Z-axis lead screw was removed, it was lubricated with grease.

Fig 4.7: Z Axis Lead Screw Rear

Section

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6. Jib Strip was removed, and its projection was welded to repair the locking mechanism.

Fig 4.8: Guideways and Jib Strip Fig 4.9: Vertical head jib strip

Fig 4.10: Gas Welded part Fig 4.11: Jib strip adjustment
screw

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7. The lubrication pump was removed from the machine, disassembled and its gear

mechanism which was found jammed, was kerosene dipped to make it work. The

lubrication pump sends oil to all moving mechanical components. It receives command

signal which starts the motor-gearbox assembly.

Fig 4.12: Lubrication Pump assembly

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4.2 Completed Objectives

The following summary shows the results that can be observed:

1. User PC can be used to operate the X and Y axes.

2. The X and Y axis drives are now working.

3. The main contactor now does not need overriding to function.

4. The lubrication pump has been repaired.

5. The rusting from Z axis guideways has been removed.

4.3 Remaining Objectives

We will target the following objectives from here on:

1. The jib strip needs to be worked on to enable the Z axis motion.

2. To repair the spindle drive.

3. To repair the pneumatic system of the machine.

4. Enable pneumatic tool holding and ATC.

5. Setup the pneumatic work holding devices.

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 CHAPTER 5

5.1 References

[1]. Mikell P. Groover, Fundamentals of Modern Manufacturing: materials, processes and

systems, 4th ed., John Wiley and Sons, Inc., USA.
[2]. A. Ghosh, A.K. Mallik, Manufacturing Science, Second Edition, East-West Press Private
Ltd., New Delhi.
[3]. Denford TRIAC CNC Milling Machine Manual.
[4]. Mach3 CNC Controller Software Installation and Configuration Manual Version 3.

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