The Milling Machine

Care and Maintenance of Milling Cutters The life of a milling cutter can be greatly prolonged by intelligent use and proper storage. Take care to operate the machine at the proper speed for the cutter being used, as excessive speed will cause the cutter to wear rapidly from overheating. Take care to prevent the cutter from striking the hard jaws of the vise, chuck, clamping bolts, or nuts. Whenever practical, use the proper cutting oil on the cutter and workpiece during operations, since lubrication helps prevent overheating and cutter wear. Keep cutters sharp. Dull cutters require more power to drive and this power, being transformed into heat, softens the cutting edges. Thoroughly clean and lightly coat milling cutters with oil before storing. Place cutters in drawers or holders so that their cutting edges will not strike each other. Never operate a cutter backwards.

Checklist Before you enter work area Put on safety glasses Tie back loose hair and clothing Remove jewelry including rings, bracelets, and wristwatches Do not use any piece of equipment until instructor has demonstrated proper operational procedures and individual safety rules Do not use any equipment or tools that are broken and report any broken equipment or tools immediately

Checklist Before machining a part While setting up work, install the cutter last to avoid being cut. When installing or removing milling cutters, always hold them with a rag to prevent cutting your hands. Make sure you have the correct tool for the job. Secure the tool properly. Make sure all tool positions have been properly initialized. Verify the NC program on the computer before machining. Remove all loose parts and pieces from the machine. Remove adjusting keys and wrenches from the machine. Close the safety shield.

Checklist Before machining a part Perform a dry run. Set the spindle motor switch to lowest manual speed setting. Make certain there is no work piece in place. Run the NC program to make sure all the moves make sense before running the program with a work piece in place. After completing the dry run, properly secure the work piece to the machine. Keep fluids away from all electrical connections, electronic or electrical devices, the computer, and nearby electrical outlets.

Checklist While machining a part Do not touch moving or rotating parts. Do not place or remove anything from the work area while machine is running. Press the Emergency Stop button before re-opening the safety shield. Only open the safety shield after the spindle has stopped rotating. Press the Emergency Stop button whenever changing tools or mounting or removing a work piece. Pull the Emergency Stop button out only after closing the safety shield. Keep all unauthorized persons away from the work area. Always leave work area clean and orderly.

CNC Speed and Feed Capabilities Machines CIM Machining CNC Speed and Feed Capabilities Super Prolight 1000 Linear Feed Rate 0.1 – 75 ipm (2 – 1905 mm/min) Circular Feed Rate X,Y Rapid Feed 75 ipm (1905 mm/min) Z Rapid Feed Speed Range 0 - 5,000 RPM Prolight 1000 Linear Feed Rate 0.1 – 25 ipm (2 – 635 mm/min) Circular Feed Rate 0.1 – 18 ipm (2 – 457 mm/min) X,Y Rapid Feed 50 ipm (1270 mm/min) Z Rapid Feed 40 ipm (1016 mm/min) Speed Range 0 - 5,000 RPM M103 * moves spindle to up limit M102 * moves table to front limit M101 * moves table to left limit M112 Home Z M111 Home X Project Lead The Way, Inc. Copyright 2008

CNC Prolight Z Axis Stepper Drive Motor Safety Shield Cross Slide 1 Z Axis Stepper Drive Motor Safety Shield Cross Slide Spindle Motor Spindle Head X Axis Stepper Drive Motor Y Axis Stepper Drive Motor 1 4 2 5 3 6 4 2 5 3 6 7 7

Manual Control Panel Manual Spindle Speed Emergency Stop Machines CIM Machining Manual Control Panel Manual Spindle Speed Emergency Stop Manual to CNC Switch Project Lead The Way, Inc. Copyright 2008

Adjusting a Machinist Vise Machines CIM Machining Adjusting a Machinist Vise As you tighten the yellow draw bolt into the blue cross bar the front vise jaw will close. The draw bolt has a limited distance of travel. If the draw bolt has reached its limit and has not tightened against the stock material, the blue cross bar must be adjusted to the next location on the rack. Note: The blue cross bar has enough play to move side to side and get stuck in the outside holes in the body. If this happens, the draw bolt will not be able to adjust to another location on the rack. The cross bar must be re-centered in the underneath gap in order to move around. Project Lead The Way, Inc. Copyright 2008

Other Vises / Hold Downs Low Profile Clamping Kit Step Blocks and Strap Clamps 2 Axis Pneumatic Vise One Axis Pneumatic Vise

Loading / Changing a Quick Change Collet Move the Z axis to a safe location Press the emergency button Open the safety shield Insert the chuck lock pin

Loading / Changing a Quick Change Collet Machines CIM Machining Loading / Changing a Quick Change Collet -Rotate the collet until the silver dot on the collet lines up with the locking pin hole -Two pins inside the collet will line up with the groove on the tool holder -With the collet locking pin still in place, tighten the collet ring -REMOVE the locking pin Project Lead The Way, Inc. Copyright 2008

Edge Finder in Tool Holder Milling Bits Specialty Tools Common Tools Double End Bit Roughing End Mill Long End Mill Engraver Edge Finder in Tool Holder

Machine Zero / Home +Z +X +Y -X -Y -Z

Part Zero +Z +X +Y -X -Y -Z

CNC Machine Axes PRZ Part Reference Zero +Z Origin 0,0,0 -Z +X +Y -Y

Top View Part Reference Zero (PRZ) Position Yp D= tool diameter Machines CIM Machining Part Reference Zero (PRZ) Position Yp D= tool diameter - x offset = D/2 Cutting Tool - y offset = D/2 Top View (0,0,0) PRZ Position Work Piece Ym Xp Part Axes Xm Machine Axes Project Lead The Way, Inc. Copyright 2008

Part Reference Zero (PRZ) Position Machines CIM Machining Part Reference Zero (PRZ) Position Zp Front View Xp Work Piece (0,0,0) PRZ Position Note: x offset = y offset = D/2 z offset= 0 Project Lead The Way, Inc. Copyright 2008

Machines CIM Machining Checking PRZ Send the Mill to a point above the x and Y zero to make sure the center of the cutting tool is over the top front corner. Project Lead The Way, Inc. Copyright 2008

Using an Edge Finder True Spin Not Touching Material Machines CIM Machining Using an Edge Finder True Spin Not Touching Material Offset Spin (Jump) Touching Material Load the edge finder in the mill Load the material in the vise Close the shield Manually turn on the spindle in the software at suggested speed for the edge finder (typically no faster than 1000 rpm) Lower the edge finder down past the negative edge of the material Move in .1 increments (Step B) toward the material until the edge finder jumps over. Back off .2 (Step B x 2) (or until the edge finder again spins true) Move in .001 increments (Step A) toward the material until the edge finder jumps over. Back off .002 (Step a x 2) (or until the edge finder again spins true) Note: Most edge finders have a diameter of .2 leaving the bit at -0.1 offset Edge finders are used to find X & Y Edge, not Z (Top) Surface Project Lead The Way, Inc. Copyright 2008

Tool Library Machines CIM Machining Project Lead The Way, Inc. Setting up the tool library properly is a critical step. Once the tool library is setup it does not need to be changed unless a new tool is loaded into a an existing tool holder. During setup the tool is defined by its geometry, size, number of teeth and relative length (Height Offset). Some of the information in the tool library is simply used when verifying programs. For instance, the NC program only directs the center of the tool so the verify program needs to know the diameter of each tool to show how much material is removed. The tool offsets and tool numbers, however, are very important when running programs with multiple tools. Each tool must be defined with a Tool Height Offset. Project Lead The Way, Inc. Copyright 2008

Machines CIM Machining Tool Setup The first step in setting up a tool library is to home the machine. The homing process will send the mill to a known position along all three axes. Follow the steps below to home the machine. Select Setup in the menu bar and then Set/Check Home Hold the Control key and type H Right click on the Jog Control Panel and select Set/Check Home Select the Home icon from the tool bar Home Project Lead The Way, Inc. Copyright 2008

Machines CIM Machining Tool Height Offsets When a tool offset is established, the control program calculates its height move using the offset. Where does the mill spindle go when it is directed to a height of .5? Tool Height Offset Project Lead The Way, Inc. Copyright 2008

Machines CIM Machining Tool Setup Wizard A wizard is available for setting up tools. Select Tool - Setup Tool Wizard from the main menu. Click Next The first tool established a reference height. Project Lead The Way, Inc. Copyright 2008

Machines CIM Machining Tool Setup Wizard To put the reference tool in the spindle, click here. Click on Next. Project Lead The Way, Inc. Copyright 2008

Machines CIM Machining Tool Setup Wizard Offset gage - Works as a continuity check. The light shines when a complete circuit is made by touching the tool and table. Click Next to continue. After inserting the reference tool, use the jog control panel to put the end of the cutting tool on the top of the block. Project Lead The Way, Inc. Copyright 2008

Tool Setup Wizard Remove the Reference tool and then select Next. Machines CIM Machining Tool Setup Wizard Remove the Reference tool and then select Next. You’re Done! Note that the Z coordinate in the Position Panel changes to zero. The current height is now the reference point. All other tools heights will now be compared to this. Project Lead The Way, Inc. Copyright 2008

Machines CIM Machining Tool Setup Wizard If the tool library has other tools defined, you may now select them to set the tool height offset. If the tool is not in the library, you will need to set it up. Project Lead The Way, Inc. Copyright 2008

Setting Up the Tool Library Machines CIM Machining Setting Up the Tool Library Type in a tool description. Enter the diameter. Select the tool number. This will be identified as tool 1 (M06T1). Project Lead The Way, Inc. Copyright 2008

Setting Up the Tool Library Machines CIM Machining Setting Up the Tool Library Select the type of tool. An End Mill has a flat bottom. Center cutting is recommended since plunging is often required. A Bull Mill has a nose radius on its corners - Define the radius here. Project Lead The Way, Inc. Copyright 2008

Setting Up the Tool Library Machines CIM Machining Setting Up the Tool Library Select the type of Tool An engraving tool is a type of tapered cutter. Define the taper angle A Ball Mill has a constant radius (1/2 diameter) on its end. Define the diameter at its end point A Standard Drill (118° Point). Project Lead The Way, Inc. Copyright 2008

Setting Up the Tool Library Machines CIM Machining Setting Up the Tool Library Load the tool in the spindle and set the parameters. Project Lead The Way, Inc. Copyright 2008

Setting Up the Tool Library Machines CIM Machining Setting Up the Tool Library Jog the machine so the tool is touching the top of the reference point (Tool offset Gage) Project Lead The Way, Inc. Copyright 2008

Setting Up the Tool Library Machines CIM Machining Setting Up the Tool Library Set the tool Height offset by clicking Current Z. Project Lead The Way, Inc. Copyright 2008

Setting Up the Tool Library Machines CIM Machining Setting Up the Tool Library Note that the position panel shows a z height of zero. The control software has calculated the difference between the reference tool and tool 1. Project Lead The Way, Inc. Copyright 2008

Setting Up the Tool Library Machines CIM Machining Setting Up the Tool Library Tool Height offset Continue setting up as many tools as necessary in the library. Any time that a tool is removed from the tool holder (not the spindle) the height offset must be reset. Now lets take a closer look at some more options in the tool library. Project Lead The Way, Inc. Copyright 2008

Machines CIM Machining Setup Tool Library Station locations are used for mills equipped with automatic tool changers. Identify tool material (high speed steel is a good general purpose tool). Number of teeth (flutes) in the cutting tool. Always apply any changes before continuing to the next tool. Project Lead The Way, Inc. Copyright 2008