Retrofitting Conventional Lathe to CNC Machine

Abstract

The development of modern technologies in computer software and hardware as well as the integration of these technologies into industrial lines has proven that more accurate; speed and efficient products can be formed. This research addressed the concept of numerical control and the concept of traditional and programmed lathe machines and how they work, as well as the mechanical and electrical components of numerical control machines and the concept of the programming language used in this thesis. Traditional lathe (Type: C0616 - 450*160 mm - 0.5 Kw Spindle motor - 0.05 mm Accuracy) has been retrofitted into a 0.04 mm CNC programmed lathe, with two stepper motors (Model 57HS22-A-1.8 Degree-2.2 NM) added for both the Z and X axles and designed new parts to fit the motors and install it on the machine body, also on the electrical and electronic level, a new control box containing protection circuits and control card (Mach3 breakout board) which translates the program to electrical signals, in addition to the stepper motors drivers and variable frequency driver that controls the main engine (Spindle motor). As well as has been installed switches and sensors (LM8-3002PB-PNP-NC-10 ~ 30 VDC) to act as limit and emergency switches and connected the machine to the Mach3 program running on the computer. As a practical application, a program of mechanical parts was taken as samples and produced on machine after retrofitting and similar machine. The results were a safe and better performance, reduced production time to more than 50%, higher accuracy and saving more than three times the cost.