Final Year Project: CNC CD Cutting Machine Design and Implementation

This document details a final year Mechatronics Engineering project from Ain Shams University, focusing on the design and implementation of a CNC CD cutting machine. The project involved a team of students and was supervised by Dr. Farid Abdel Aziz Tollbah. The assignment covers the entire project lifecycle, from initial concept and AutoCAD design to material selection, manufacturing, coding, circuit design, and testing. The student, acting as co-leader, contributed significantly to the mechanical design, material selection, manufacturing, and testing phases. The project aimed to create a machine capable of cutting CDs according to AutoCAD designs, offering potential applications in marketing, advertising, and even 3D printing. The report includes detailed descriptions of the design process, material choices (including the substitution of Teflon for aluminum to reduce power consumption), and the assembly and testing phases. The student also emphasized the importance of safety guidelines and teamwork. The project culminated in a presentation and demonstration to a panel of professors, integrating electrical and mechanical knowledge. The project helped the student learn to work in a team and apply engineering principles to a real-world problem.

Career Episode 2
(CD cutting CNC machine)
Introduction:
Career Episode 2.1:
I did my bachelor’s in Mechatronics Engineering from one of the oldest and prestigious
universities in Egypt known as Ain Shams University. Mechatronics Engineering has been
included in the curriculum in 2004 and I graduated with Mechatronics degree being the third
alumni of the university. Our final semester project was CD cutting CNC machine and it took 6
months to complete the project from January 2008 to June 2008.
Background:
Career Episode 2.2:
I was asked to choose a topic for our final year project that would require knowledge gained in
our 5 years of engineering. The professor asked us to divide into groups of 4-5 students and
choose a topic of project that would require implementing knowledge gained and presenting the
project before a panel of professors who would give grades to our project. The project consisted
of the following subparts:
 Milling machine mechanical design
 Selection of the construction material
 Milling machine manufacturing
 Coding, circuit design, block diagram

 Trouble shooting and testing
Career Episode 2.3:
The topic chosen was for graduation project in Ain Shams University. The prerequisites for
graduating was finalising the objectives. As a team member I designed the CNC CD cutting
machine that will be able to cut a CD according to the AutoCAD design. The information is
communicated through coded software developed. There are some advantages of CNC CD
cutting machine like CD design can be printed on real CD by implementing it on AutoCAD. The
design can be used for marketing and advertising purposes. Additionally, the machine can be
used in 3D printing if it can be adjusted from 2D to 3D.
Career Episode 2.4:
Dr. Farid Abdel Aziz Tollbah supervised our project. He was the referred to as computerized
numerical Control professor. The project leader of the project was Hani Amin and my team
members were Nader Adeeb, Mina Sameh and Amir Wahib.
Prof. Dr. Farid
Abdel Aziz Tolbah
(Project
Hani Amin (Project
Leader)

Activities involving creation of the project:
Career Episode 2.5:
I was selected as the co-leader and I helped in designing CNC machine using AutoCAD, selected
materials for different parts of the machine, did manufacturing of different parts, and done
machine performance testing and assembling various parts of the machine. As a part of the team,
I performed the following tasks:
 CNC machine designing in AutoCAD
 Material selection for several moving parts of the machine
 Understand dimensions of the project is necessary to demonstrate design capabilities and
technical knowledge. This helped in ensuring the quality of design
 Ensured teamwork capacity by working in a team
 Did the cost analysis to ensure that the manufacturing and design of the machine is done
within the budget set before
 Selection of workshops and research to manufacture different parts
 Assembling the machine
 Performed testing of the machine and
 Presented the project before the professors
Career Episode 2.6:
Nader Adeeb (Co-
leader)
Mina Sameh
(Team Member)
Amir Wahib
(Team Member)

To begin with the project, I started researching on CNC 2D printer machine from university
library, textbooks, internet sources and training materials gained from the lectures. My father has
a pharmaceutical distribution company that used CDs for marketing the products that required
CD cover printing for serving two purposes, one is advertising and second is to differentiate
between CD. From this, I gained the idea of transforming the boring round shape of CD to
unique designs that would reveal data stored there.
Career Episode 2.7:
At first, I started with the design of machine using AutoCAD as the design software that was
suggested by our supervisor Professor Farid Tollbah and then defined the components that were
required to create the machine like 2 AC geared motors, a steel table and so on. We seeked
approval of following design elements:
 Software used for the design is AutoCAD.
 A vertical milling machine with motor specification of 0.25 BHP AC was used.
 A square 2 mm cutting tool was used in a steel machine head for quality cutting
 Requirement of two AC geared motors, one for moving the milling table on both X-axis
and the other for rotary motion of CD in Y-axis.
 To facilitate X-axis precision lead screw mechanism was used.
 Rotary motion was provided to mount steel table on saddle with CD holder.
 After designing the machine I seeked approval from our project supervisor.
Career Episode 2.8:
I along with one of the team member Mina Sameh reviewed our supervisor’s feedback that
helped us in cutting down price of CD. I reviewed two materials that was used in the milling

table and decided to use Teflon in place of Aluminum that would also reduce the power
consumption by 50%. Additionally, the Lead Screw mechanism was also reviewed that would
reduce the friction in the lead screw mechanism thereby reducing the power consumed.
Career Episode 2.9:
Material selection was done after completing the design of the CNC machine. Our teaching
assistants and technicians of the workshop helped us as the project involved use of different
machines for drilling, milling and cutting. The other two members of my team, Hani and Ramy
helped me in developing the codes of in AutoCAD.
Career Episode 2.10:
The machine was assembled after completing the parts design. Mina helped me in assembling
the machine while Hani and Ramy worked on the electrical motors. I took the initiative to inform
the team members about machine safety guidelines so that accidents can be avoided. Then
machine guards were installed to eliminate eye injuries. I have also taken measures to remind
team members about safety rules.
Career Episode 2.11:
Along with co-leader, I was assigned the role of creating a forum where monthly progress of the
project additionally with challenges and issues will be noted to meet the CPS of the project. The
final step of the project included documentation of all the research and technical details of the
project noted in a booklet along with preparing presentation that was presented before a panel of
professor. The professor would evaluate our project based on presentation and demonstration of
the project. The evaluation was done at the end of the year.

Summary:
Career Episode 2.12:
This project gave me a chance to implement all the knowledge and principles that I have gained
in my 5 years of engineering and the project was made by integrating electrical and mechanical
knowledge. I have also learnt to work in a team after the completion of the project. I had several
contributions to the project including developing idea and mechanical design of the project,
fabricating the parts, calculating cost and power, documentation and knowledge distribution,
informing other team members about safety guidelines of the machine and managing the team to
complete the project within targeted time.