Transcript The Milling Machine

The Milling Machine
Computer Integrated Manufacturing
© 2013 Project Lead The Way, Inc.
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
Prolight 1000
Super Prolight 1000
Linear Feed Rate
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
– 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
CNC Prolight
1 Z Axis Stepper
2
3
4
5
6
7
Drive Motor
Safety Shield
Cross Slide
Spindle Motor
Spindle Head
X Axis Stepper
Drive Motor
Y Axis Stepper
Drive Motor
1
4
5
6
2
3
7
Manual Control Panel
• Manual Spindle
Speed
• Emergency Stop
• Manual to CNC
Switch
Adjusting a Machinist Vise
Other Vises / Hold Downs
Low Profile Clamping Kit
One Axis Pneumatic Vise
Step Blocks and Strap Clamps
2 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 Tools
Specialty Tools
Double End
Bit
Long End
Mill
Engraver
Roughing
End Mill
Edge Finder in
Tool Holder
Common Tools
Machine Zero / Home
+Z
+X
+Y
-X
-Y
-Z
Part Zero
+Z
+X
+Y
-X
-Y
-Z
CNC Machine Axes
+Z
-Z
+X
+Y
-X
-Y
PRZ
– Part Reference
Zero
– Origin
– 0,0,0
Part Reference Zero (PRZ) Position
Yp
D= tool diameter
Top View
- x offset = D/2
(0,0,0) PRZ Position
Ym
Cutting Tool
Work Piece
Xp
Xm
- y offset = D/2
Machine Axes
Part Axes
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
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.
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 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
Tool Height Offsets
When a tool offset
does the
isWhere
established,
the
mill spindle
go
control
program
when it is its
calculates
directed
to ausing
height
move
height
of 0.5?
the
offset.
Tool Height Offset
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.
Tool Setup Wizard
To put the
reference
tool in the
spindle,
click here.
Click on
Next.
Tool Setup Wizard
Offset gage - Works
asClick
a continuity
Next tocheck.
continue.
TheNote:
light Itshines
when
is sometimes
anecessary
complete circuit
to clickisthe red
madestop
by touching
the
button first.
tool and table.
After inserting the reference tool, use the jog control
panel to put the end of the cutting tool on the top of the
block.
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.
Tool Setup Wizard
If the tool library
has other tools
may
Ifdefined,
the toolyou
is not
now
them
in
theselect
library,
you
to set
thetotool
will
need
set it
height offset.
up.
Setting Up the Tool Library
Enter the
diameter.
Type in a tool
description.
Select the tool
number. This will be
identified as tool 1
(M06T1).
Setting Up the Tool Library
Select the type of
tool.
An End Mill has
a flat bottom.
A Bull Mill has a
Center cutting is
nose radius on
recommended
its corners since plunging is
Define the radius
often required.
here.
Setting Up the Tool Library
Select the type
of Tool
Define the taper
angle
A Ball Mill has a
Define the constant radius (1/2
A Standard Drill
diameter at itsdiameter) on its end.
(118° Point).
end point
An
engraving
tool is a
type of
tapered
cutter.
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 Library
Set 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 Library
Station locations
are used for
mills
equipped
Identify
tool
Number
of teeth
with
automatic
material
(high
(flutes)
in the
tool
changers.
speed
steel is a
cutting
tool.
Always
apply
good
general
any changes
purpose tool).
before
continuing to the
next tool.