This master´s thesis deals with design of small CNC milling machines and comparing CNC tabletop milling machines in the world market. It is also done design of small CNC milling machine through the use of contemporary and modern trends, used in design of machine tools.

This thesis deals with the structural design of small model CNC milling machines. The work includes research modeller CNC milling machines available primarily on the Czech market, on whose basis are then selected the appropriate parameters for machine design. The thesis contains further structural calculations, selection of appropriate components, production drawings and 3D model that shows the final solution of constructed facility.

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El texto completo de este trabajo no está disponible en el Repositorio Académico UPC por restricciones de la casa editorial donde ha sido publicado. / This work proposes the design of a low cost semi-industrial three degree of freedom CNC vertical milling center (VMC) with non-ferrous metal machining capabilities. The design seeks to mitigate the difficulties that acquiring a commercial industrial CNC can present, such as large dimensions, high cost and complications in its transportation within the plant. The proposed machine will be made up of 1 NEMA 23 stepper motor for each X, Y and Z axis, and will be controlled by open source firmware using an ATMEGA 2560 microcontroller. Likewise, the working area will be 320x180mm and will have a precision 100 microns with semi industrial capacities. This design is aimed at small and medium-sized companies that are looking for a low cost non-ferrous CNC milling machine that in turn has the quality, performance and precision of an industrial one.

STATEMENT OF PROBLEM: The production of full arch dental models through Rapid Additive Prototyping (3D Printing) have been questioned for their accuracy in the past decade. PURPOSE: To compare the accuracy of 3D printed and milled dental models, using a digital metrology software. MATERIALS AND METHOD: A mandibular arch typodont was duplicated to produce a conventional Type IV dental stone model. This Model was scanned to create a digital model and an STL file was created which would be sent to Milling and 3D printing machines.15 models were printed using 3 different 3D printing companies and 10 models Milled with a CNC (Computerized Numeric Controlled) milling machine. Each model was scanned and a digital model was created. These scanned models were then super imposed to the scan of the master model through an inspection software (Geomagic Control X, 3D Systems) for accuracy of production. RESULTS: The mean difference in measurement in Absolute Gap, by either of the two methods of prototyping adopted, (0.075 mm for 3D Printed and 0.084 mm for milled) are well below the clinically acceptable values mentioned in previous literature. The means in absolute tooth distance discrepancy for both prototyping methods (0.0361 mm for 3DPand 0.0353 mm for Milled) were not statistically significant. CONCLUSION: 3D printed dental models were more accurate statistically than milled dental models. In general, the mean accuracy for both methods of rapid prototyping is within clinical tolerance and both are clinically acceptable.

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<p> High-speed machining (HSM) concepts were developed in response to productivity, quality and cost concerns. Significant advancements in controls and machining technologies have recently come together to enable the wide spread use of HSM on the plant floor. However, with the advancement of HSM technology, dynamic problems associated with modern machine-tool structures have not been fully addressed and are currently limiting performance in some applications. <p> A key aspect in the modelling of HSM processes is capturing the dynamics of the system during cutting. Machining over a wide range of rotational speeds necessitates the inclusion of many more higher modes in the system than traditionally considered. In addition many of the instruments used to assess performance such as force dynamometers are not designed to measure the cutting forces at high rotational speeds and hence the specific cutting force values being used are often times not being estimated properly. </p> <p> Thus the focus of this research is to develop a new procedure for predicting the specific cutting forces in the end-milling process for high-speed machining. An improved mechanistic model to predict the specific cutting force using acceleration data captured from the workpiece fixture was developed. The development of the new procedure has also lead to an improvement in the extraction technique used to establish the modal parameters of a machining system. This new extraction technique was found to be more flexible and easier to use than other available techniques. </p> <p> The new procedure was investigated to test the effect of choosing the number of modes of the improved modal parameters extraction technique on the estimation of the specific cutting force. The effect of filtrating the acceleration signal and the importance of including the run-out of the cutting tool in the model were also investigated. </p> <p> The new procedure was tested on different setups and with different cutting force models. Experimental validation of the proposed estimation procedure was carried out, analyzed and compared to the open literature. The new procedure was found to be more accurate while being easier to implement. </p> / Thesis / Doctor of Philosophy (PhD)

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