PCB Milling Machine
Amjad Qablawi
Jameel Nassar
Mahyoob Sarrawi
Alaa Zagha
Supervised by : Dr. Jamal Kharrousheh















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Introduction
PCB laminates ,Drilling and Milling Operations
Electrical Components
Mach3 Software
Mechanical Components
Outline
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Introduction
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What is PCB Milling Machine ?
What is CNC ?

What is the aim of the project ?





Objectives :
Reliable PCB’s with low cost
High accuracy
Safety
Flexibility
Fast (time saving )
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Introduction






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Introduction















Two main components :
1_ Laminate
2_ Copper foils
Content of the PCB:-

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Base materials :-
Laminates  consist of :
Resins:
Phenol, Polyester,
epoxy and polyimide.
Fillers:
Paper and glass fiber.
 




Content of PCB :-


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Copper foils:-

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Carbide bits .
Tungsten carbide .
Advantages  of using them:-
Much harder than HSS.
Very durable.
Scratch resistance.
Keep it hardness against temperature.
Tools dealing with PCB:-

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The PCB fabrication process involves a number of mechanical operations:-
Milling.

MECHANICAL OPERATION :-

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Drilling.
The quality of drilled holes depends on:
Quality of laminate and drill bit.
Machine accuracy.
Drilling techniques.


MECHANICAL OPERATION :-

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Drilling mechanism :-


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Electrical component 


Software 
Micro controller
Driver
Power supply 
Stepper motors





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The power supply is to feed the system with power . It converts 220 V AC to 24 V DC and 1.6-14 A DC .

Electrical Component 

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The Micro Controller : 
To translate the orders from the Computer to the motors driver 
24V DC
Electrical components 

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  Drivers :
-The main function of the drive is to convert the step command input signals to patterns of currents in the motor winding.
-Reverse the direction of the motors .






Electrical components
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Optocouplers 
 
 							
						
					cct the coil
Electrical Components

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The stepper motor (Nema 23) :






We used the Bipolar one.
Electrical components 

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Spindle (the drill).
 220V AC , manual control (on/off).
30,000 rev/min . 350W
Electrical components 

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 Software 





parallel port
cadsoft eagle pcb designer
mach3
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 Software 
What is Cadsoft eagle PCB designer?
With eagle we can do many things, starting from creating and designing and circuit and convert the the graphics to G-code.

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Software
What is mach3?
Mach3 is a software package that runs on a pc and depends on his work on G-code

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Software
What is G-code?
defined by instructions on where to move

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Software (pcb design )






- CAD Software: Used to design the circuit. The output of CAD are drawings.
- CAM Software: CAM software analyzes the CAD drawing, takes input from the machinist or programmer, and outputs g-code for the machine controller.

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Software





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Software
 Design schematic circuit 






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CopperCAM software






Frame

Mechanical Design


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Galvanized steel

Mechanical Design





Green MDF (wood)
Galvanized steel
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Transmission systems

Mechanical Design



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Bearings 

Mechanical Design







Rails 
Lead screw 
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Mechanical Design

Rails 
Y, Z & X rails
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Mechanical Design



Coupler
Bearings 
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Mechanical Design


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	Total price (NIS)	Pieces No.	The price of each  piece	Pieces Name
	300	3	     100	Stepper Motors
	200	1	200	Drilling motor (spindle)
	2000	1	2000		Project design
	900	3	300	stepper motor driver
	350	1	350	break out board
	200	1	200	Power supply
	200	 	200	Other costs
	4150 	 	 	Total cost 

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Total cost of the project and it’s feasibility:







Problems
Choosing the right mechanical design for the project
High prices of some components.
 the mach3 free version doesn’t give all the benefits of the paid one .
Choosing the right driver circuits for the motors. 
Difficult found Milling and Drilling tool.


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Problems &Recommendation






 Recommendation
Improve the mechanical design of the project
Using a vacuum or something like that to eliminate the tiny copper parts that still remaining on the PCB after cutting and milling.
Looking for a technique to change the PCB layers between upper layer and bottom layer automatically.
 Ability of welding electronic parts foot.
Using laser instead of Drilling.

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Thank All for your Attention







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