CNC Circuit Mill/Manufacturing Instructions

1 Preparation

• Edit

https://docs.google.com/spreadsheet/ccc?key=0AlpsBarfpPkzdFk5aDY3dHM0eEhfZHNkWVppdV9EelE

2 Structure

• Cut Angle 0.125" x 1.5" x 1.5"

To 14 pieces of 360mm length

To 10 pieces of 160mm length

To 1 piece of 60mm length

• Cut Square Tube 0.125" x 1.5" x 1.5"

To 1 piece of 200mm length

• Cut Flat Bar 0.125" x 6" x X

• Drill Angle Template

60mm long, 0.125" x 1.5" x 1.5" steel angle.

Use pilot bit. Differentiate the 2 holes as A and B. When looking at the angle's inner perspective, hole A should be up and to the left of hole B.

ANGLE HOLE A - Mark and drill hole A on one angle side, 20mm from the inner joining edge of angle, close to the end of the angle.

ANGLE HOLE B - Mark and drill hole B on the other angle side, 20 from the inner joining edge of angle, 40mm apart (distance is angle-parallel) from hole A.

• Tube Template

0.125" x 1.5" x 1.5" x 180mm steel tube.

All holes drilled with only pilot bit. Keep angle template usage consistent by keeping its 2 tube contact faces the same for all holes for a given surface. Ensure tube is on flat surface. Ensure tube template usage consistency.

TEMPLATE REFERENCE HOLE Use angle template hole A to drill reference hole near end of tube.

TEMPLATE MOTOR HOLE Mark and drill 8mm tube-parallel from reference hole.

TEMPLATE STEPPER HOLES Mark 15.5mm tube-parallel from reference hole then drill 2 holes each 15.5mm tube-perpendicular from mark.

TEMPLATE SHAFT HOLE Mark 70mm tube-parallel from reference hole then drill 1 hole at mark using angle template hole A.

TEMPLATE FRAME HOLE Mark 170mm tube-parallel from reference hole then drill 1 hole at mark using angle template hole A.

TEMPLATE ANGLE HOLE Drill 1 hole using angle template hole B while hole A is set to the template shaft hole with rod.

• X Angles (aka the steel angle pieces that go horizontally from side to side of the circuit mill)

0.125" x 1.5" x 1.5" x 360mm steel angle (4)

Drill reference, frame, and frame angle holes in all.

Drill shaft holes in 2.

Drill stepper holes in 1.

0.125" x 1.5" x 1.5" x 160mm steel angle (7)

Drill reference, shaft, and shaft angle holes in all.

Drill stepper holes in 1.

Drill motor holes in 1.

• Y Angles (aka the steel angle pieces that go horizontally front to back of the circuit mill)

0.125" x 1.5" x 1.5" x 360mm steel angle (4)

Drill reference, frame, and frame angle holes in all.

• Z Angles (aka the steel angle pieces that are oriented vertically upwards)

0.125" x 1.5" x 1.5" x 360mm steel angle (6)

Drill reference and frame holes in all.

Drill frame angle holes in 4.

Drill shaft holes in 2.

Drill stepper holes in 1 as if the upper shaft hole was the reference hole.

Drill new shaft holes in 2 as if the upper shaft hole was the reference hole.

• Sleeve Bearing (reduces friction between the pair of support shafts and the moving platform for each axis)

Drill the 12 sleeve bearings through the XYZ setup to achieve alignment.

• Leadscrew Nut (converts rotary motion of the leadscrew into linear motion where the nut travels along the axis of the leadscrew)

Drill the 3 leadscrew nuts through the XYZ setup to achieve alignment.

• Plates (used to increase the rigidity of the pair of moving angles in each axis setup)

Drill the 3 plates through the XYZ axes setup to achieve alignment.

2 Software Summary

3 Get Git 3 Get rxtx 2.1-7 binary files 3 Get ruby programming language 3 Get grbl make files 3 Get gctrl 3 Get Processing

3 Copy the rxtx .jar and .so files from the 2.1-7 directory into the processing directory 3 Change gctrl code to have fixed port recognition 3 Make clean, make (compiled by this point), and make flash (firmware uploaded by this point) the grbl files into the arduino uno

3 Open Processing>gctrl>run 3

4 Getting Git

• Open Terminal and type:

sudo apt-get install git-core

4 Getting RXTX 2.1-7 Binary Package

• Go to this webpage:

http://rxtx.qbang.org/wiki/index.php/Download

• Download the RXTX 2.1-7r2 (stable) Binary Package

• Extract the downloaded zip file to a directory of your choosing

4 Getting RUBY Programming Language

• Open Terminal and type:

sudo apt-get install ruby1.9.1

• Restart the computer for the changes to take place

4 Getting GRBL Files

• Open Terminal and type:

git clone https://github.com/damellis/grbl.git grbl

4 Getting Gctrl

• Open Terminal and type:

git clone https://github.com/damellis/gctrl.git gctrl

4 Getting Processing

• Go to this webpage:

http://processing.org/download/

• Download the latest version of Processing to a directory of your choosing

4 Moving RXTX files

• Navigate to the rxtx-2.1-7r2 folder.

• Copy RXTXcomm.jar

• Navigate to the Processing folder>modes>java>libraries>serial>library

• Paste RXTXcomm.jar, replacing the existing version

• Navigate to the rxtx-2.1-7r2 folder>Linux>i686-unknown-linux-gnu

• Copy librxtxSerial.so

• Navigate to the Processing folder>modes>java>libraries>serial>library>Linux32

• Paste librxtxSerial.so, replacing the existing version

4 Modifying Gctrl

• Open the Gctrl folder

• Open gctrl.pde in gedit

• Change a part of the code as annotated in the following:

Serial port = null; //change starts

String portname = "/dev/ttyACM0"; // Linux, Arduino Uno

//change ends

boolean streaming = false;

4 Modifying GRBL Files

• Navigate to the GRBL folder

• Open "Makefile" in gedit

• Edit the PROGRAMMER line as:

PROGRAMMER = -c stk500v1 -P /dev/ttyACM0 -b 115200

4 Flashing GRBL

• Open Terminal and navigate to the GRBL folder (ex. by using the "ls" and "cd" commands)

• In Terminal, type:

make clean

make

• Connect the Arduino Uno to the computer via USB cable

• In Terminal, type:

make flash

• Disconnect the Arduino Uno

4 Running GRBL

• Navigate to the Processing folder

• Open and run Processing, setting the sketchbook folder as the folder in which the gctrl folder exists

• In Processing, open gctrl using File>Sketchbook>

• Connect the Arduino Uno to the computer via USB cable

• In Processing, run gctrl using Sketch>Run

• Note: For any function of gctrl, press and hold down the key for the popup windows to populate.