the milling machine. care and maintenance of milling cutters the life of a milling cutter can be...
TRANSCRIPT
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.
ChecklistBefore you enter work area
Put on safety glassesTie back loose hair and clothingRemove 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
ChecklistBefore 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.
ChecklistBefore 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.
ChecklistWhile 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
Super Prolight 1000
Linear Feed Rate– 0.1 – 75 ipm – (2 – 1905 mm/min)
Circular Feed Rate– 0.1 – 75 ipm – (2 – 1905 mm/min)
X,Y Rapid Feed– 75 ipm – (1905 mm/min)
Z Rapid Feed– 75 ipm – (1905 mm/min)
Speed Range– 0 - 5,000 RPM
Prolight 1000Linear 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
CNC Prolight
Z Axis Stepper Drive Motor
Safety ShieldCross SlideSpindle MotorSpindle HeadX Axis Stepper
Drive MotorY Axis Stepper
Drive Motor
1
2
3
4
5
6
7
14
5
2
3
6
7
Manual Control Panel
• Manual Spindle Speed
• Emergency Stop
• Manual to CNC Switch
Adjusting a Machinist Vise
Other Vises / Hold DownsLow 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
Milling Bits
Engraver
Long End Mill
Double End Bit
Roughing End Mill
Edge Finder in Tool Holder
Specialty Tools Common Tools
Machine Zero / Home
+X
-X
+Y
-Y
+Z
-Z
Part Zero
+X
-X
+Y
-Y
+Z
-Z
CNC Machine Axes
-X
+X
-Y
-Z
+Z
+Y
PRZ – Part Reference
Zero– Origin– 0,0,0
Xp
Yp
Part Reference Zero (PRZ) Position
D= tool diameter
(0,0,0) PRZ Position
Work Piece
Xm
Ym
Machine Axes
Part Axes- y offset = D/2
Top View - x offset = D/2
Cutting Tool
(0,0,0) PRZ Position
Xp
Zp
Note: x offset = y offset = D/2z offset= 0
Front View
Work Piece
Part Reference Zero (PRZ) Position
Checking PRZSend 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.
Using an Edge Finder
True Spin
Not Touching Material
Offset Spin (Jump)
Touching Material
Edge finders are used to find X & Y Edge, not Z (Top) Surface
Tool Library
Tool SetupThe 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
Tool Height Offsets
Tool Height Offset
Where does the mill spindle go when it is directed to a height of .5?
When a tool offset is established, the control program calculates its height move using the offset.
Tool Setup WizardA wizard is available for setting up tools. Select Tool - Setup Tool Wizard from the main menu.
The first tool established a reference height.
Click Next
Tool Setup Wizard
To put the reference tool in the spindle, click here.
Click on Next.
Tool Setup Wizard
After inserting the reference tool, use the jog control panel to put the end of the cutting tool on the top of the block.
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.
Tool Setup Wizard
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.
Remove the Reference tool and then select Next.
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.
Setting Up the Tool Library
Select the tool number. This will be identified as tool 1 (M06T1).
Type in a tool description.Enter the
diameter.
Setting Up the Tool Library
Select the type of tool.
A Bull Mill has a nose radius on its corners - Define the radius here.
An End Mill has a flat bottom. Center cutting is recommended since plunging is often required.
Setting Up the Tool Library
Select the type of Tool
Define the taper angle
An engraving tool is a type of tapered cutter.
A Standard Drill (118° Point).
A Ball Mill has a constant radius (1/2 diameter) on its end.
Define the diameter at its end point
Setting Up the Tool Library
Load the tool in the spindle and set the parameters.
Setting Up the Tool Library
Jog the machine so the tool is touching the top of the reference point (Tool offset Gage)
Setting Up the Tool LibrarySet the tool Height offset by clicking Current Z.
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.
Setting Up the Tool Library
Tool Height offset
Setup Tool LibraryStation locations are used for mills equipped with automatic tool changers.
Number of teeth (flutes) in the cutting tool.
Identify tool material (high speed steel is a good general purpose tool).
Always apply any changes before continuing to the next tool.