Rancang Bangun Sumbu Tambahan A dan C serta Modifikasi Sistem Kontrol pada Mesin CNC EMCO TU-3A Berbasis Mach 3 Controller

Abstract

This research aims to improve the performance and capability of the EMCO TU-3A CNC machine through modification of the control system and the addition of the A and C axes so that the machine can operate as a 5-axis CNC milling machine. The EMCO TU-3A CNC machine is a learning unit widely used in educational institutions, but has limitations in the control system, processing capabilities, and is not compatible with modern CAM software. Modifications were made by redesigning the mechanical and electrical systems, including calculating the drive motor requirements, selecting the Mach3 V2.0 Breakout Board, and using the DM860H stepper driver. A safety system was also designed to ensure safe machine operation. The addition of the A and C axes was carried out through 3D design using SolidWorks, selecting a 1:100 and 1:120 ratio gearbox, and fabricating components using various machine tools. Calibration was carried out using the gear calculation method and automatic calibration on Mach3. The calibration results showed an increase in accuracy and precision on the X, Y, and Z axes up to 0.003 mm, as well as 0° rotation precision on the A and C axes with a setting of 1600 microsteps. This research successfully revived the previously suboptimal TU-3A CNC machine, while simultaneously improving the machining capabilities of workpieces with complex geometries.