Design and Control Aspects of a new Meso-Milling CNC Machine

Mechanical design concepts are presented for a new desktop meso-milling CNC machine. Concept selection criteria are discussed which highlight some of the challenges in mechanical configuration design, instrumentation and control. In conjunction, the conversion of an existing production 3-axis desktop milling machine into a meso-milling CNC machine is detailed. The retrofit process, which features electrical as well as mechanical design, control and instrumentation setup, helps to identify the design problems which must be solved, when creating a new desktop meso-milling machine tool which offers improved resolution, accuracy and repeatability while facilitating manufacturing flexibility. iii Acknowledgments I would like to thank Professor Beno Benhabib for his advice, expertise and encouragement in this endeavour as well as my colleagues in the CIM lab at the University of Toronto. In particular, I would like to thank Matthew MacKay for his invaluable advice and help in troubleshooting the electronics of the CNC machine as well as to thank him for his imprompt