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Micromill CNC Milling Machine

1. 2 free serial COM ports e 1 free parallel printer port Micromill CNC Milling Machine User s Manual Section 3 CNC Machine and Software Installation 23 3 VR CNC Milling Software Installation Follow these instructions to install the VR CNC Milling software on your personal computer 1 Switch on your PC and start Windows 95 98 if required 2 Insertthe VR CNC Milling CD ROM into your CD ROM drive If your CD ROM is set to autorun the install program will start move to section 5 If the install program does not automatically start continue to section 3 Double click the left mouse button on the My Computer icon In the My Computer window find your CD ROM drive icon usually labelled D or E and double click the left mouse button on this icon The contents of the CD ROM will be displayed in a new window Double click the left mouse button on the file named Setup exe to start the installation program Click the square button next to the Install VR CNC Milling title and follow the on screen instructions Select the Micromill as the CNC machine used for default software configuration Click in the Micromill checkbox so a tickmark is displayed Select the area of your hard disk where the VR CNC Milling software can be installed together with any program group names We strongly recommend that you allow the Denford installer to create its own directory if you have not used any Denford software previous
2. Boring Cycle Absolute Zero Incremental Command Feed per Minute Feed per Revolution Return to Initial Point in Canned Cycle Return to R in Canned Cycle Circular Pocket Circular Pocket Rectangular Pocket Rectangular Pocket Code listing full and correct at the time of printing Micromill CNC Milling Machine User s Manual 15 M Codes List Note Not all M codes may apply to your CNC machine M code Function M Program Stop M 1 Optional Stop M 2 Program Reset M 3 Spindle Forward clockwise M 4 Spindle Reverse counter clockwise M 5 Spindle Stop M 6 Automatic Tool Change M 8 Coolant On MQ9 Coolant Off M10 Vice Work Clamp Open M11 Vice Work Clamp Close M13 Spindle Forward and Coolant On M14 Spindle Reverse and Coolant On M19 Spindle Orientation M20 ATC Arm In M21 ATC Arm Out M22 ATC Arm Down M23 ATC Arm Up M24 ATC Drawbar Unclamp M25 ATC Drawbar Clamp M27 Reset Carousel to Pocket One M3 Program Reset and Rewind M32 Carousel CW M33 Carousel CCW M38 Guard Door Open M39 Guard Door Close M62 Auxiliary Output 1 On M63 Auxiliary Output 2 On M64 Auxiliary Output 1 Off M65 Auxiliary Output 2 Off M66 Wait for Auxiliary Output 1 On M67 Wait for Auxiliary Output 2 On M70 Mirror in X On Notall M codes listed M71 Mirror in Y On are available all M M76 Wait for Auxiliary Output 1 Off codes marked with an M77 Wait for Auxiliary Output 2 Off asterisk will be M8 Mirror in
3. WORK WORKPIECE The actual material being milled Quite often this work is also secured onto a sub table The work is sometimes referred to as the billet or stock WORKPIECE DATUM Used as a zero reference point on the real billet All machining co ordinates originate from this point when offset files are used WORKPIECE OFFSET A file containing X Y and Z values that can shift the entire three dimensional co ordinate based grid system used by the CNC machine See OFFSET WORD atirei ana A combination of a letter address and digits used in a CNC program ie G42 M04 etc VIRTUAL REALITY ee A fully interactive three dimensional computer based simulation of a real world object or event AN Oia aa Denford Compiled CNC file extension xnc A compiled file is a FANUC Miller file that is formatted to allow 3D elements such as the 3D Viewer to run as quickly as possible XNC files can also be used to drive an attached CNC machine when run through the VR CNC Milling software Z TOOL OFFSET nois See Tool Offset 108 Glossary Section 16 Micromill CNC Milling Machine User s Manual 17 Index A Address characters list c csscscssessseseseeees 100 Advantages Of CNC sssi 10 AUD ModE 5 sits inssaiaraiaraaiia anette 67 Cc Changing COM ports oc 90 Changing tools software procedure 50 Clamping work miteebites issis 56 CNC definition and overview uu 10 CNC file 2D simulation vo eees
4. Look at top of machine column Y Axis trigger bolt attached to machine saddle 82 Maintenance Section 13 Micromill CNC Milling Machine User s Manual 13 Gib Strip Adjustment A gib strip is an angled section of metal or plastic tapered along its length which is fitted to one side of a machine slide One gib strip is fitted to each of the three machine slides on your Micromill Essentially driving one of these wedges further along a slide will gradually decrease the amount of free play in the axis The photo below shows a gib strip fitted to the Z axis of a Micromill machine column Photo showing location of Z axis gib strip Gib strip thin end Guide pin Gib strip wide end Locking screw During the day to day use of your Micromill wear will occur in each of the gib strips This wear is normal and if checked regularly will not affect the performance of your machine Denford recommends that the gib strips be checked annually Any slack present in the slides should be rectified by adjusting the gib Strips as described on the following pages Checking the Condition of the Gib Strips As the gib strips wear down varying degrees of free play will become noticeable in each of the three machine axes You can quickly judge the slack available in each slide by holding the table saddle and machine head at their extreme ends Try to move or wobble them from side to side across t
5. Set Tool Type option to display a secondary menu of possible graphic choices Highlight and click on the title of the tool type to set the graphic in the right panel of the Tooling Library window Changing the Tool Colour To change the colour allocated to the new tool click the right mouse button on the new tool title to display the pop up menu Move the cursor down the list highlighting the Set Tool Colour option The Color window will be displayed Click one of the coloured squares in the Basic colors area then click the OK button The new tool colour is shown in the oval marker to the left of the new tool title in the Tooling Library window as shown above The same colour is also applied to the tool number when the tool is being used in the Machine Tooling window Micromill CNC Milling Machine User s Manual Section 6 Configuring Tools in the Software 35 6 Using the Machine Tooling window When a tool profile is transferred from the Tooling Library window into the Machine ing window it is assigned a tool number Tool profiles must be transferred according to the tool numbers specified in your CNC file In the case of ATC equipped CNC machines this will also be the number of the carousel pocket into which the tool profile is placed 36 Configuring Tools in the Software Section 6 Tool profiles from the Tooling Library are added to the Machine Tooling window where they become rea
6. T M codes etc other than co ordinate based commands AXIS AXES voces The planes of movement for the cutting tool usually referred to as X horizontal left and right parallel to the front edge of the table Y horizontal forward and backwards parallel to the side edge of the table and Z directly vertical Combinations of all 3 allow precise co ordinates to be described Axes are also referred to as slides or Slideways BILLET cresccsiriesteriesteoteetenn The actual material being machined sometimes referred to as the workpiece or stock BLOCK iiaiai A collection of program words that collectively describe a machining operation A single program line in the CNC file CHARACTER eeeteseeseeeee A number letter or symbol as entered into a CNC program CIRCULAR INTERPOLATION G code term for a programmed arc movement COMMAND shassi A signal or group of signals instructing one step operation to be carried out CONTEXT SENSITIVE When the type of input signal of an event automatically changes the output signal CO ORDINATES use Positions or relationships of points or planes Co ordinates are usually described using three numbers referring to the X Y Z axes e g the co ordinate 23 35 45 means X axis 23 units Y axis 35 units and Z axis 45 units CNG riina aaa Computer Numerical Control CNC RILE ara fei etii The sequence of commands describing the manufacture of a part on a CNC machine written usi
7. fitted to machine door ap Interlock guard switch casing mounted behind front panel accessible from beneath machine An interlock guard switch is fitted to the front machine door The switch casing itself is attached behind the lower machine panel accessible from beneath the front of the machine with the guard Switch lock fitted around the guard door handle The switch must be manually released to enter the working area when the 24 volt circuit has failed and the door is clamped electrically Note For manual interlock release the power supply must be switched off 1 Remove security screw A B or C whichever is easiest to reach using the supplied Torx T 20 adapter 2 Insert a 2 5mm diameter tool such as a small flat screwdriver into the hole until it pushes the manual release lever 3 Whilst holding the tool against this manual release lever open the guard 4 Remove the tool from the hole and replace the security screw Interlock Trip Lever Micromill CNC Milling Machine User s Manual Section 2 Safety Features 15 3 Unpacking amp Lifting your Micromill Cut the top of the delivery box open and remove any packaging carefully To obtain better access to the Micromill remove all the sides from the delivery box Lift the Micromill from the packaging Denford recommends that two or more persons are used to lift the Micromill one at each side panel as illustrated in the diagram below Always use sensible li
8. when looking down to increase the height of the pad Levelling the machine using Anti vibration Pads 18 CNC Machine and Software Installation Section 3 Micromill CNC Milling Machine User s Manual 3 Connecting your PC to the Micromill A Warning Your PC must be equipped with hardware that allows it to 1 run the Virtual Reality CNC Milling software 2 be physically connect to the Micromill To check the PC specification required please see page 23 PC Terminology The COM ports on your PC may be labelled as Serial ports The Parallel port on your PC may be labelled as the Printer port Do NOT use a sole 9 to 25 pin adaptor cable in place of the RS 232 cable supplied with your machine The RS 232 cable supplied with your machine must always be used since this cable features crossovers on some of the pin connections Micromill CNC Milling Machine User s Manual Do not connect cables between any electrical hardware with the mains power switched on since this could damage the hardware Your Micromill CNC machine is controlled using a standard IBM compatible PC personal computer In this role the PC can be referred to as the machine controller computer Ideally the PC you intend to use should be placed next to your Micromill with easy access to a mains power supply To connect your PC to the Micromill electrical control box 1 Connect the elements of your PC together as described in
9. 1 5 HP 1 1Kw Axis stepper motors 200 steps rev 20 CNC Machine and Software Installation Section 3 Lax The Mains Supply The electrical control box is delivered with standard mains Specification cable connected directly into the isolator The cable should be fitted with a standard 13 amp plug suitable for the mains power supply A Warning Do not connect cables between any electrical hardware with the mains power switched on since this could damage the hardware All electrical connections should only be made by a suitably qualified electrical engineer Electrical Access Plate The Micromill electronics are located in the rear of the machine To access the electronic hardware remove the electrical panel access plate on the rear of the machine If the machine has previously been switched on wait atleast 5 minutes before attempting to open the access plate Hazardous voltages can still exist immediately after switching off the power Electrical Drawings The Electrical Diagrams for your Micromill CNC machine are not included in this manual they are delivered separately in the standard equipment box supplied with your Micromill CNC machine Micromill CNC Milling Machine User s Manual 3 Removal of Protective Coatings Once your Micromill has been sited and connected electrically the protective coatings must be removed to prepare the machine for running The protective coatings applied to the slideways and b
10. Support Monday to Friday 8 30am 4 30pm GMT For USA please contact Denford Inc 815 West Liberty Street Medina Ohio 44256 USA Telephone 330 7253497 Fax 330 7253297 E mail service denford com Technical Support Monday to Friday 8 30am 4 30pm Eastern Internet http www denford com 88 Technical Support Section 14 Micromill CNC Milling Machine User s Manual 14 Troubleshooting COM Port Set up Machine Communication Note Your screen may display the message Error 50 Mint 3 28 Disconnect or similar depending on the hardware fitted If the VR CNC Milling software cannot connect to your Micromill CNC machine check the following 1 Power is reaching your Micromill and the electrical control box is Switched on 2 The RS 232 cable is connected to a valid serial port If so identify whether itis COM1 or COM2 3 The VR CNC Milling software is set to read the correct COM port number Follow the instructions on page 110 to change the COM port numbers in the software 4 The COM portis functioning correctly and itis active in your computers BIOS assessable on computers during initial boot up The method used for accessing this information will depend on the hardware fitted in your computer check your computer documentation for details on how to access your BIOS 5 The LED display status on your Micromill control card Refer to the instructions on page 112 An L or 8 should be displayed If the LED
11. The equivalent of the pc return key ERRO Rainaa eni The deviation of an attained value from a desired value G CODE wciiuanccanaiin The programming language understood by the machine controller REEDRATE viewissiceiecrcreis The rate in mm min or in min at which the cutting tool is advanced into the workpiece For milling and drilling the feedrate applies to the reference point on the end of the axis of the tool PILE farh An arrangement of instructions or information usually referring to work or control settings FORMAT ieten The pattern or way that data is organised FN Gaietan FANUC Miller file extension fnc Contains G and M codes describing the machine and cutting operations G CODE inaina A preparatory code function in a CNC program that determines the control mode HARDWARE osses Equipment such as the machine tool the controller or the computer HOME aiaia Operation to send the axes of the CNC machine to their extreme limits of movement Defines the co ordinate based grid system of the CNC machine Commonly referred to as homing the machine or sending the machine to its home position INCREMENTAL sess Incremental programming uses co ordinate movements that are related from the previous programmed position Signs are used to indicate the direction of movement INPUT iiinn The transfer of external information data into a control system INTERFACE viriito The medium through which the control computer directs the mac
12. X Off performed at the end of M81 Mirror in Y Off a program block ie M98 Sub Program Call after any axis M99 Sub Program End and Return movement Code listing full and correct at the time of printing Micromill CNC Milling Machine User s Manual Section 15 Appendix 99 15 List of Program Address Characters N Program Sequence line number X Primary motion in X axis Y Primary motion in Y axis Z Primary motion in Z axis G Preparatory functions Incremental distance parallel to X axis J Incremental distance parallel to Y axis K Incremental distance parallel to Z axis R Radius M Miscellaneous functions T Tool numbers S Spindle speeds F Feed rates 100 Appendix Section 15 Micromill CNC Milling Machine User s Manual 15 Denford Directives Directives are program terms defined by Denford Limited They are used to help generate the 2D and 3D graphics used by the machine controlling software BILLET This directive allows a billet that appears in a simulation window to be given a size The billet definition should be placed at the start of a program after the units of measurement have been set Example G21 BILLET X190 0 Y 90 220 0 This sets the measure to metric Note if set to Imperial the units would be inches and defines the billet as1 mm long by 99mm wide with a depth of 28mm SUBPROGRAM This directive allows a program with a non numeric
13. buttons which when clicked open the various information windows windows are shown in Or operate features in the software These toolbars and windows the example can be freely moved around inside the main program window to screenshot create your own screen layout The top titlebar of the software should read Virtual Reality CNC Milling followed by the name of the CNC machine that can be controlled by the software If itdoes not read Micromill continue as outlined below The name of the CNC machine that can be controlled by the VR CNC Milling software can be changed by clicking Setup Setup Machine Parameters Note a password may be required to earn te access this part of the software In the Machine Properties oa idi Window right click on the name of the CNC machine you want to control in future then click the Set As Active Machine option Refer to your separate VR CNC Milling Software User s Manual or the helpfiles on the software CD ROM for more detailed information The default password to access the Machine 30 Getting Started Section 4 Micromill CNC Milling Machine User s Manual 5 Loading and Saving a CNC File Loading a CNC File To load a previously saved CNC file click File Open Select the directory used for storing the CNC file using the Look in panel Click on the name of the file required its name will appear in the File name dialogue box Click the Open button to load the
14. by Denford Limited for loss damage or injury caused by any errors in or omissions from the information supplied in this manual Please note that any screenshots are used for explanation purposes only Any numbers wording window or button positions may be different for the configuration of the VR CNC Milling software being used to control your Micromill CNC machine This manual is written using European English Any comments regarding this manual should be referred to the following e mail address customer_services denford co uk Any updates to this manual will be posted in the Downloads section of the Denford website http www denford co uk Micromill CNC Milling Machine User s Manual Contents 7 Conventions used in this Manual Mouse Usage Underlined text Quotation Marks Bold Text Square Brackets Bold Square Brackets 8 Contents When asked to left click on a menu tile or object click the LEFT mouse button ONCE When asked to right click on a menu tile or object click the RIGHT mouse button ONCE When asked to double click on an object click the LEFT mouse button TWICE When reference to either a left mouse button or right mouse button click command is omitted always perform one click with the left mouse button This is used to show key words The full definition of any terms are given in the J argon Buster helpboxes Similar helpboxes are also used to display any Important Notes or Tips to help
15. describes the sequence of operations that the machine must perform in order to manufacture the component 2 The part program is loaded into the machines computer called the controller At this stage the program can still be edited or simulated using the machine controller 3 The machine controller processes the part program and sends Signals to the machine components These direct the machine through the required sequence of operations necessary to manufacture the component What are the advantages of CNC CNC systems are automated and very accurate Once programmed a CNC machine will perform repeat tasks until instructed to stop Each component produced will be exactly the same size and shape saving money on designing any jigs and fixtures that might have otherwise been required Using CNC machines can reduce waste material since a CNC machine is much less likely to make an error than a human operated machine CNC machines can also run 24 hours a day if necessary with no signs of fatigue Companies can estimate the manufacturing costs for CNC production much more accurately compared to a production line with conventional production machines J argon Buster CNC refers to Computer Numerical Control the automatic system used to control a machine tool A Part Program is a list of coded instructions which describes how the designed component or part will be manufactured The part program is also referred to as the CNC fi
16. illustrated descriptions explaining the use of each G and M code 32 Loading or Creating a CNC File Section 5 Micromill CNC Milling Machine User s Manual 6 Using the Tool Library Upon initial installation the default Tooling Library profiles available are as follows Metric Tooling Slot Drills Imm 2mm 3mm 4mm 6mm 8mm 10mm 12mm End Mills 1mm 2mm 3mm 4mm 6mm 8mm 10mm 12mm Ball Noses 1mm 2mm 3mm 4mm 6mm 8mm 10mm 12mm Inch Tooling Slot Drills 1 16 0 0625 1 8 0 1 3 16 0 1875 1 0 25 5 16 0 3125 3 8 0 375 1 2 0 5 End Mills 1 16 0 0625 1 8 0 125 3 16 0 1875 1 4 0 25 5 16 0 3125 3 8 0 375 1 2 0 5 Ball Noses 1 16 0 0625 1 8 0 125 3 16 0 1875 1 4 0 25 5 16 0 3125 3 8 0 375 1 2 0 5 Data relating to all the tools used with your CNC file must be entered into the Tooling Library and Machine Tooling windows in order to perform any of the tasks outlined below e Simulating a CNC file in 2D or 3D e Running a CNC file on a Virtual Reality CNC machine e Running a CNC file on a real CNC machine The Tool Library contains the list of tool profiles that the VR CNC Milling software will let you use with your CNC machine The data from each tool profile relates to a real cutting tool The most common tool profiles are installed as standard although you may need to edit some
17. is then fastened to this secondary table Used as a safety feature to prevent damage occurring to the actual machine table should a problem occur when milling For example a sheet of MDF Sometimes referred to as a temporary table or platen Micromill CNC Milling Machine User s Manual Section 16 Glossary 107 16 Glossary SOFTWARE riisiin Programs tool lists sequence of instructions etc TABLE tinier waviranietaren The horizontal platform upon which work is secured sometimes referred to as the machine table T CHANNEL woes There are three slots or channels upside down T shapes which run horizontally along the machine table parallel with the X axis just under the surface They are used when fitting the datum plate and clamps in position on the machine table MEE NUT ierant An upside down T shaped block found on clamps which fit into the T channels on the machine table TOOL OFFSET ues When machining allowances must be made for the size of tools being used since they all differ in length The tool offset is the amount the Z value must be moved or offset so that all the different cutting tool tips used line up with each other so they can all be used by one CNC file See OFFSET TOOLPOST The holder for the various cutting tools TRAVERSE ccssiessetiiesscedien Movement of the cutting tool through the 3 machine axes between cutting settings TXT retose et Standard Windows text only file extension txt
18. manoeuvring the tool The cutting tip just touches the ea surface ofthe sub table a wor H gees js oa as J Machine The shaded Sub table Head area depicts the A lt a Br upper surface of Soest the sub table wee we j A E Machine e Sub table eg sheet of MDF In this example the tool reference position has been chosen as the upper surface of a sub table This position can be easily reached by all the different tool profiles we intend to use with the CNC file Section 11 Configuring Offsets 65 11 Configuring the Tool Length Offset The Z Tool Length Offset value is saved to the tool profile itself viewed in the Machine Tooling window not the workpiece machine offset file viewed in the Work Piece Offsets window More detailed information regarding the theory and practice of configuring Tool Length Offset files can be found in your separate VR CNC Milling Software User s Manual To transfer the Z co ordinate value into the Tool Length Offset 1 Specify the Tool Length Offset Value From the Machine Mode window click the Z Offset button The Set Offset window used for entering the tool length offset value is displayed The Z co ordinate currently shown in the Machine Mode window is the value including any sign that must be entered into the dialogue box Note that the software will automatically display this value in the
19. of their values to match the exact specifications of the real cutting tools you have available s To display the Tooling Library window click the y A 4 Tool Library button shown right from the ae Options toolbar General Layout of the Tooling Library window Click on the squares to expand the list of available tool profiles and data or the squares to collapse any open lists To highlight a tool profile click on its title A graphic will be displayed in the right panel relating to the type of tool selected To close the Tooling Library window click the Tool Library button from the Options toolbar Tool Library Highlighted Tool Data Highlighted Tool Window Titlebar Tooling Librafy Diameter 2 000 length 50 000 Tool Length offset 0 000 Flute length 25 000 Flute Count 2 Maximum tool Life 50 Current tool Life 0 Slot Mill 4mm Slot Dal x Tool Profile List of available Highlighted Tool Colour Marker Tool Profiles Graphic Panel Micromill CNC Milling Machine User s Manual Section 6 Configuring Tools in the Software 33 6 Viewing Tool Data To display the data allocated to a specific tool click the square next to the text title of Tool Demeler ni 50 the tool required Teoleri aod Tool Length Offset 0 000 To edit a value in the tool data list double click the left mouse button on the data 25 000 title required The Tool 25
20. or 3D Denford directives see section 7 pages 38 to 39 written in the CNC program step B Tooling data is taken E Establish communications and home the CNC machine from the configuration of s the software tooling see section 8 pages 40 to 45 step C i F Prepare any tooling hardware for the Micromill see section 9 pages 46 to 51 G Load the billet onto the machine table see section 10 pages 52 to 58 H Configure the ea offset fle ani tool length offsets see section 11 pages 59 to 66 Manufacture the part see section 12 pages 67 to 70 Micromill CNC Milling Machine User s Manual Section 4 Getting Started 25 4 General Layout of Micromill Components General Layout of Micromill CNC Machine below Electrical Panel Access Plate f at rear of machine cabinet sy Machine Controller PC Q O Enclosed Guard Emergency Stop Button EEC Interlock Guard Switch behind front panel Inside the Micromill CNC Machine Cabinet below Drawbar Access Z Axis Motor a y le Slide X axis onor of Saddle Table Leadscrew aR Machine Head Spindle Machine Column Column Slide Z axis Cross Slide Y axis Column Base 3 i X Axis Close up view N e Motor under Machine machine Table table ie os Motor 26 Getting Started Section 4 Micromill CNC Milling Machine User s Manual 4 Micromill Fr
21. s Manual EC Declaration of Conformity The responsible person Mr N J H Crowther Business Name Denford Limited Address Birds Royd Brighouse West Yorkshire HD6 1NB UK Declares that the machinery described Manufacturer Denford Limited Model Name Micromill Series CNC Milling Machine Serial Number please refer to warranty card and or machine casing conforms to the following directives EC Machinery directive 89 392 EEC as amended by directive 91 368 EEC and directive 93 44 EEC CE marking directive 93 68 EEC and low voltage directive 73 23 EEC and the following standards BS EN 68204 1 1993 and complies with the relevant health and safety requirements Signature WN car Position within company Director General Manager Signed at Denford Limited Birds Royd Brighouse West Yorkshire HD6 1NB UK 16 Glossary ABSOLUTE sivsssdiscsavsii cence In absolute programming zero is the point from which all other dimensions are described ALLEN HEAD wee A hexagon shaped hole on the head top of a set screw These are tightened and loosened using allen keys wrenches ARC A E A portion of a circle ATG Suvsiccaiesiceeneatvectensieae Automatic Tool Changer AUTOMATIC CYCLE A mode of control operation that continuously runs a cycle or stored program until a program stop or end of program word is read by the controller AUXILIARY FUNCTION The function of the CNC machine ie F S
22. the workpiece datum has been registered correctly More detailed information regarding the theory and practice of configuring Workpiece Offset files can be found in your separate VR CNC Milling Software User s Manual icromill CNC Milling Machine User s Manual Section 11 Configuring Offsets 63 11 Configuring the Tool Length Offset The tool length offset files each contain a single Z value A separate tool length offset file must be configured for every tool we want to use They allow us to establish a common workpiece datum position no matter what length of tool is used with the CNC file Select a point on your machine table sub table or billet that can be reached by all the tools you intend to use All tool length offsets are configured against this common tool offset reference point When values are entered into each individual Z length tool offset file each tool will use this reference point as their zero co ordinate along the Z axis Itis this figure that compensates for the differences in length when various tools are used together on the same job Machine Head Home Position T9917 AE e ea Tool2 y 7 Difference in length between tools 1 and 2 J Ps ON A os ee oh eee MB ee es Le F aes Tool Length Plane of Tool Length Offset value Tool Offset value for Tool 2 Reference for Tool 1 Position M4 Billet Billet Y a e Sub table Sub table e
23. tool on the Spindle Micromill CNC Milling Machine User s Manual Section 9 Preparing Tooling Hardware 49 9 Manual Tool Changing with the Software Lax Calling a Manual Tool Change Ensure the tool profiles and tool numbers have been setin the VR CNC Milling software to match the real tooling hardware and tool numbers used with your CNC machine See the separate VR CNC Milling Software User s Manual or the helpfile for further information Note Easier access to the tooling components may be obtained by moving the machine head halfway down the Z axis Safety First A Never open the safety guard door and enter the working area when the spindle or machine axes are moving Lax 50 Preparing Tooling Hardware Section 9 When manually moving jogging the axes Before beginning a manual tool change operation we recommend you home all machine axes To home the machine axes click the Home tab on the Machine Mode window Click the Z Axis ONLY button The machine head will move up along the Z slide until it has reached its home position Click the X Axis ONLY button The machine table will move along the X slide until it has reached its home position Click the Y Axis ONLY button The machine table will move along the Y slide until it has reached its home position Machine Tooling Edit Tool Data Change Tool Type gt Change To This Tool Remove Tool Move Tool T
24. you use your Micromill CNC machine Quotation marks are used to specify any software menu title and window selections e g click the File menu would mean click the left mouse button once when the cursor is positioned over the File menu label When a sequence of menu commands are requested the menu and option names are separated by a vertical line for example Click File Open would mean open the File menu then click on the Open option Bold Text is used to show any characters or text that must be entered into the software e g type file1 would mean type the word file1 into the appropriate text entry box Square brackets are used to show any on screen software button selections e g Click the OK button would mean click the left button of the mouse once when the cursor is directly pointing over the button labelled OK Bold square brackets containing text show individual keys to press on your qwerty keyboard e g press Enter would mean press the Enter key Ifa number of keys must be pressed in sequence they are shown with plus signs outside any square brackets e g press Alt Enter would mean press the Alt key first followed by the Enter key second If a number of keys must be pressed simultaneously they are shown with plus signs inside any square brackets e g press Alt Enter would mean press both the Alt key and Enter key together at the same time Micromill CNC Milling Machine User s Manual 1 Introducin
25. your original PC manufacturers operating manual At this stage your PC should not be switched on 2 The PC must be physically connected to the Micromill using the Supplied RS 232 cable This is the long thin cable fitted with 25 pin female connector at one end and a 25 pin male connector at the opposite end 3 Connect the male end of the RS 232 cable to the 25 pin female port on the right side panel of your Micromill This port is labelled RS 232 4 Connect the remaining female end of the RS 232 cable to the 25 pin male COM2 port on your PC The COM ports are usually situated on the back panel of your PC Note that some personal computers may be fitted with 9 pin male COM ports If this is the case a 25 pin to 9 pin adapter available from most good computer electrical retailers must be fitted to allow the cable to be connected to the PC If you cannot identify any of the ports on your PC please refer to your original PC manufacturers operating manual for further guidance Do not confuse the 25 pin female parallel printer port on your PC with the 25 or 9 pin male COM ports A schematic diagram illustrating these component connections is shown on pages 22 Section 3 CNC Machine and Software Installation 19 3 Connecting the Mains Supply Data Panel Electrical Connection Data Mains supply required Single Phase 220 240 Volts 8 Amps 50 60 Hz Cable required 3 Core 1 5mm per core Spindle motor
26. 2 Data window will be displayed as shown on the right Click the cursor in any of the yellow tool data fields delete the old value and enter the new data Click the OK button to close the window and apply any changes made The options available in the Tool Data window are as follows Tool Diameter The diameter of the tool defined in mm or Any data changes made inches see diagram below are applied to identical tools from both the Tool Tool Length The length of the tool measured from the end of Library window and the the tool collet to the cutting tip of the tool defined in mm or Machine Tooling inches see diagram below window Tool Length Offset The Z tool length offset value defined in mm or inches The objective of the Z tool length offsets is to allow different tool profiles to cut in the correct place on the billet despite their obvious differences in length Each tool is set against a common zero reference The value indicated defines the position of this zero reference but only applies to the tool profile being viewed Flute Length The length of the flute measured from the beginning of the flute to the cutting tip of the tool defined in mm or inches see diagram below hate ha The number of flutes on the tool see diagram elow Maximum Tool Life The working life of the tool stated in hours Current Tool Life The current life of the tool stated in hours Flute Count To
27. 3 If the S collet needs to be installed follow as outlined below cn Feed the drawbar through the hole at the top of the machine head Ensure the washer is fitted to the drawbar in the correct orientation Reach under the machine head and insert the collet into the spindle Begin to thread the collet onto the drawbar see diagram left Do not completely tighten the collet At this stage you only need to finger tighten the drawbar 3 Place the desired tool into the collet If necessary tighten the drawbar by hand until the tool is held in the collet Rage 4 Fit the spindle bar supplied into one of the holes on the threaded spindle body under the machine head Fita 1 2 or adjustable spanner around the drawbar hexagon bolt on the top Cutting of the machine head T 5 Using the spindle bar to stop the spindle from rotating tighten the drawbar hexagon bolt by turning itin a clockwise direction Take care not to over tighten the drawbar hexagon bolt see diagrams below u ZEN J ZX c Fi View Safety First T X Cz Direction A Use adjustable Never open the safety or 1 2 guard door and enter spanner G r Drawbar the working area when hexagon the spindle or machine O N bolt axes are moving Machine Head 6 Check the tool is secure in the collet and the collet is secure in the spindle before using the tool 48 Preparing Tooling Hardware Section 9 Micromill CNC Milling Machine
28. 3 Micromill CNC Milling Machine User s Manual 13 Gib Strip Adjustment Y Axis Gib Strip Adjustment Method 1 Release the gib strip locking screw positioned on the left side of the machine saddle shown below Location Look at left side of machine saddle Turn anticlockwise to release or clockwise to tighten locking screw when viewing the face of the locking screw DF mi ig 2 Push the wider end of the gib strip further into its channel to eliminate the free play in the slideway The gib strip is accessed from the front of the machine table shown below Remember that a slight degree of movement must be left in the slide to allow the slide to move Location CX Look at front of machine saddle sf ye yo Locking screw f Gib strip and guide pin 3 Tighten the gib strip locking screw 4 Move the machine table left and right across the saddle to ensure that the movement is smooth 5 Ifthe movement is not smooth adjust the gib strip by repeating steps 1 to 3 Run the machine table again to assess the smoothness of movement Micromill CNC Milling Machine User s Manual Section 13 Maintenance 85 13 Gib Strip Adjustment Z Axis Gib Strip Adjustment Method 1 Release the gib strip locking screw positioned on the left side of the machine head shown below Location X Look at left side of machine head Turn anticlockwise to release or clockwise to
29. CNC Milling software You start and exit the VR CNC Milling software as you would any standard Windows application 4 If VR CNC Milling has been installed using the recommended program groups the software can be started from the Windows Startbar menu in the following order click Start Programs Denford VR Milling see icon shown on left 5 Alternatively if you have setup a desktop shortcut to the VR CNC Milling software double click this icon to start the software see icon shown on left 6 Due to the amount of information that can be shown by the software we recommend a screen setting of at least 1024 x 768 in 16 bit High Colour 7 To exit the VR CNC Milling software click File Exit Important Never exit the VR CNC Milling software when your Micromill is machining or processing any operational instructions Micromill CNC Milling Machine User s Manual Section 4 Getting Started 29 4 General Layout of the Software 5 Virtual Reality CNC Milling MicroMill File Editor Edt Search Modify Preferences Setup Windows Utiities Help Ch Outputs Toolbar Machine Control Toolbar Editor Window Main Program Statusbar Options Toolbar File Control Toolbar Oe sh ICP Offsets Tooling Tool Library Block Skip Metric Continuous Made Skip Block edges of the main VR CNC Milling window The toolbars contain Not all the VR CNC i Miling software option
30. CNC file into the Editor window Fast Loading of a known CNC file The ReO pen option can be used to gain fast access to CNC files that have been loaded in previous sessions Click File ReOpen choice of filename to reopen the required CNC file Saving a CNC File To save your CNC file click File Save As Select the directory used for storing your CNC files using the Save in panel Enter the filename in the File name dialogue box using the file extension fnc then click the Save button Creating a new CNC File Click File New to begin creating a new CNC file A blank display will be created in the Editor window J argon Buster An fnc file is a FANUC milling file containing G and M codes that describe the machining operations necessary for manufacture of the part Micromill CNC Milling Machine User s Manual Section 5 Loading or Creating a CNC File 31 5 The Editor window Torx y The Editor window displays the text content of your CNC file Positioning the editing cursor Position the cursor using the four computer Cursor arrow keys Use Page Up to move to the top of the CNC file Use Page Down to move to the bottom of the CNC file Use Home to move to the beginning of the current CNC file line Use End to move to the end of the current CNC file line Editing Shortcuts CTRL X will cut any highlighted text from the Editor window to th
31. DEN FORD Total Commitment to Education and Training WorldWide Micromill CNC Milling Machine User s Manual CE approved Denford Limited reserves the right to alter any specifications and documentation without prior notice No part of this manual or its accompanying documents may be reproduced or transmitted in any form or by any means electronic or mechanical for any purpose without the express written permission of Denford Limited All brands and products are trademarks or registered trademarks of their respective companies Copyright Denford Limited Version 1 0 2000 All rights reserved Contact Information Address Denford Limited Birds Royd Brighouse West Yorkshire HD6 1NB UK Telephone General Enquiries 44 0 1484 712264 Customer Services 44 0 1484 722733 Fax 44 0 1484 722160 e mail for sales enquiries contact sales denford co uk for machine servicing enquiries contact service denford co uk for customer services and technical support contact customer _services denford co uk Notes 2 Contents Micromill CNC Milling Machine User s Manual Contents Preface C OMAGH IMPOMM ANON seevavsccrassiatesvessetesnavacscentsvecusanten evans dvtbveseceuvs devattucdeanra tontines 2 COMING nea ita T gna 3 WAMMING NOUCES cienia aa a aa 6 About this Manual it w Conventions used in this Manual ssssssssissrssssssssrsnrnnnnsnsrnrnnnnnnnsnanrsnrnn
32. Finally run the saddle forwards and backwards along the Y axis to distribute the oil along the full length of the leadscrew Look along column Pump oil along the leadscrew arrowed 74 Maintenance Section 13 Micromill CNC Milling Machine User s Manual 13 Lubrication of Leadscrews Column Z Axis Leadscrew Lubrication Using a pump action oilgun reach around the back of the column then pump oil directly onto the surface of the leadscrew Run the head up and down the column to distribute the oil Location X Look behind column View Direction Back of Machine Column Pump oil along the leadscrew arrowed Lubrication of Optional Vice Clean then lubricate directly onto the vice slideways each week using a pump action oilcan Micromill CNC Milling Machine User s Manual Section 13 Maintenance 75 13 Lubrication of Slideways Table X Axis Slideways Lubrication Run the table to the extreme left of its travel to expose the right side of the table slideways Use a pump oilcan with a flexible nozzle or an aerosol to lubricate the slideways Reaching under the table directly lubricate the exposed surfaces of the two table slideways 76 Maintenance Section 13 Run the ta ble to the extreme right of its travel to expose the left side of the table slideways Reaching under the table directly lubricate the remaining exposed surfaces of the two table slideways R
33. Manual MN a SS SS Fj Pi oe va Denford Directive Example BILLET Address example G AN J T Word example G1 i Block example N 13 G1Z 1F 109 Section 15 Appendix 97 15 G Codes List Note Notall G codes may apply to your CNC machine G codes from group are non modal they must be programmed into every program block when required All other G codes are modal they remain active through subsequent program blocks until replaced or cancelled by a G code from their particular group The G codes indicated by an asterisk are reactivated as defaults when the machine Started 98 Appendix Section 15 G Code G G 1 G 2 G 3 G 4 G20 G21 G28 G40 G41 G42 G73 G74 G76 G8O G81 G82 G83 G84 G85 G86 G87 G89 G9 G91 G94 G95 G98 G99 G17 G171 G172 G173 Group 1 Function Positioning Rapid Traverse Linear Interpolation Cutting Feed Circular Interpolation CW Circular Interpolation CCW Dwell Exact Stop Imperial Data Input Inches Metric Data Input M illimetres Reference Point Return Cutter Compensation Cancel Cutter Compensation Left Cutter Compensation Right Peck Drilling Cycle Counter Tapping Fine Boring Canned Cycle Cancel Drilling Cycle Spot Boring Drilling Cycle Counter Boring Peck Drilling Cycle Tapping Boring Cycle Boring Cycle Back Boring Cycle
34. NC file In other words the position of the workpiece datum will determine the place on the CNC machine where our part is manufactured What actually happens when program my workpiece datum position Configuring the workpiece datum position shifts or offsets the entire three dimensional co ordinate grid system used by the CNC machine The workpiece datum will now be read by the CNC machine as its zero position rather than the machine datum to find out more about the machine datum see page 41 Micromill CNC Milling Machine User s Manual Section 11 Configuring Offsets 59 11 Introducing Offsets Where should position the workpiece datum on my billet This depends on the position of the part datum set in your CNC program The part datum is the zero reference or starting point used when plotting all the co ordinates that describe the shape of your design The part datum could have been set by the programmer when manually writing the CNC program from a traditional engineering drawing or automatically set by a CAD CAM software package For example if you used the CAD CAM software package Denford MillCAM Designer your design would have been drawn within a fixed area representing the size of the billet you intend to use The software would then have generated the CNC program automatically setting the front left upper corner of this imaginary billet as the part datum In this case you would need to position the work
35. R end of the CNC file is reached CNC Milling software File Control Click the triangular P lay button from the File Control toolbar shown left 3D Simulation The 3D is configured using the Units button on the Options toolbar Check that the tool numbers and tool profiles used in the Machine Tooling window match those used by your CNC file Micromill CNC Milling Machine User s Manual x 5 000 Y 55 000 Simulation window shows a three dimensional graphical view of the billet which can be rotated into different viewing angles by the user Section 7 Simulating a CNC File 39 8 Machine Communications If errors occur when attempting to connect to your Micromill CNC machine please refer to section 14 Technical Support for help Follow these instructions to establish communications between the PC and your Micromill CNC machine 1 Before attempting to connect to your Micromill CNC machine check that the units of measurement set for the VR CNC Milling software matches the units used in both the CNC file and any tooling profiles you intend to use ie if your CNC file and tools are metric select Metric units of measurement The units of measurement setting for the VR CNC Milling software is configured using the Units button on the Options toolbar 2 Click the Machine button shown below from the Options toolbar This will establish a connection vi
36. User s Manual 9 The Quick Change Tooling System Installing a Tool in the Quick Change Holder 1 Remove the drawbar and collet as outlined on page 47 before working with the quick change tooling 2 Insert the cutting tool into the bushing aligning the flat on the cutting tool with the position of the bushing set screw Tighten the bushing set screw to lock the cutting tool in position 3 Insert the bushing assembly into the quick change holder aligning the flat on the bushing with the position of the quick change holder set screw Tighten the quick change holder set screw to lock the bushing assembly in position Quick Change Bar Hole Set Screw Installing a Tool in the Quick Change Holder Flat Set Screw Flat 2 Quick Change Bushing Na Tool Holder Cutting Tool Installing a Quick Change Holder on the Spindle 1 Thread the quick change tool holder onto the spindle until it is finger tight 2 Fitthe spindle bar into one of the holes on the spindle body under the machine head Fitthe quick change tool holder bar into one of the holes on the quick Pa change holder body 3 Using the spindle bar to stop the spindle from rotating tighten the quick change a holder using the quick change tool re PSN 2 View Direction A holder bar Take care not to over tighten the thread Installing a Quick 6 Check all components are secure before Change Holder using the
37. a COM1 or COM2 allowing the software to control your Micromill CNC machine f P Machine 3 Once communication to your Micromill has been established the Machine Mode window will appear This window is used to control the movements of the CNC machine 40 CNC Machine Control Section 8 Micromill CNC Milling Machine User s Manual 8 Homing the CNC Machine Home Mode The J og and Auto tabs will not be displayed until the machine has been configured by homing all three machine axes In addition to homing the CNC machine after ithas first been switched on we also recommend homing the CNC machine after loading or configuring any offsets Micromill CNC Milling Machine User s Manual Machine Mode Home Jog Auto x Axis ONLY Y Axis ONLY bv qa Co Ordinates Z Axis ONLY All Axes kll work Piece Co orc F600 0 5150 0 T When your Micromill CNC machine is first started the Machine Mode window will be displayed with only the Home tab active as shown above The Home tab is used for configuring the CNC machine before it can be fully used This process is commonly referred to as homing the machine or datuming each axis Each of the three machine axes is sent to their fixed zero positions This defines the three dimensional co ordinate grid system used for plotting tool area positions and the limits of movement used on the CNC machine After homing the m
38. achine the zero position of the grid is referred to as the machine datum You can find the position of the machine datum by switching the co ordinate display in the Machine Mode window to read Machine Co ordinates The position of the machine datum is achieved when the X Y and Z panels of the co ordinate display all read zero assuming no offsets are loaded Homing the CNC Machine Axes To home the machine X axis only click the X Axis ONLY button The X machine slide will move until it has found its limits of co ordinate movement To home the machine Y axis only click the Y Axis ONLY button The Y machine slide will move until it has found its limits of co ordinate movement To home the machine Z axis only click the Z Axis ONLY button The Z machine slide will move until it has found its limits of co ordinate movement To home all three axes sequentially click the All Axes button All machine slides will move until their limits of co ordinate movement have been found ro Section 8 CNC Machine Control 41 8 Co ordinate System Display Modes The Co ordinates button is used to switch between the two systems for displaying the co ordinate positions Work Piece or machine The far right panel on the statusbar displays the current setting for this button When the Units of Measurement are set to Inch the co ordinates are displayed using inches When the Units of Meas
39. aded Machine homed datumed To manufacture your part 1 Check the cursor in the Editor window is positioned at the beginning of your CNC file 2 Click the Auto tab in the Machine Mode window 3 Click the triangular Play button on the File Control Toolbar to begin the machining process File Control Toolbar Buttons File Control gt Play Pause Stop Rewind to start 4 A message window will be displayed whenever a tool change is required Wait for all machine movement to stop before opening the safety guard door then change to the new tool number requested Close the safety guard door and click the OK button in the message window to resume machining To stop machining click the square Stop button on the File Control toolbar or press the emergency stop button located on the righthand side of the Micromill front panel Read the next page for important information regarding stopping the machining process Micromill CNC Milling Machine User s Manual Section 12 Part Manufacture 67 12 Stopping the Machining Process Machining will need to be restarted if the part manufacture process is halted Follow the instruction below to restart machining If the emergency stop button is used to stop the machining process 1 Release the emergency stop button by pressing the button in whilst turning itin a clockwise direction The button will spring back out 2 A machine error window may be disp
40. ar and Collet Tooling System sssccccccencccresnnnnnnnnnnsss 46 Removing a Tool from the Drawbar Collet Installing a Tool into the Drawbar Collet The Quick Change Tooling System Manual Tool Changing with the Software ssssssssssssssssssssssisisssisisrststntnininininrnrnnrennnne 50 Section 10 Work Holding The Daten Plate ipianak eiia 52 Seting the Datum Plate rinine a iN 53 Miteebite Clamps Fi How does a Miteebite Clamp work ssssccccccccccccccccccccccnssssssss 57 Using IM tee bite Cla Mps sicivetccisdiccccsssvsscssssuccccnsasescotsdescesvss escsuvtoddconssdeicoeties ecettsaica 58 Section 11 Configuring Offsets Introducing Offsets aieiaiei eni n e a ei aaki 59 Configuring a Workpiece Offset 61 Creating a new Workpiece Offset File 62 Configuring the Tool Length Offset ssssssssssssssssssssssssssssssnsssnsnnnsnnnsnnnnnnnnnnnnnnsns 64 Section 12 Part Manufacture Manufacturing your Part Auto Mode ssssssssssssssssssssssssssssstnsrntiriririritnnnrnrernrnrnresnnesns 67 Stopping the Machining Process 68 Overriding Feedrates and Spindle Speeds cccecsesseceseeseesseesesseesseesseceneetnes 69 Micromill CNC Milling Machine User s Manual Contents Section 13 Maintenance Maintenance Schedule and Lubrication Chart osc 71 Lubrication Areas on the Micromill K Lubrication of Lea dSCrews aoreininnniiiiiatia nna aa LUDMGALION OF Slideways siimi eiriaa a a Lubrication
41. ard 76mm 3 Micromill 2000 127mm 5 1 8 Travel Z axis Standard and Micromill 2000 165mm 6 1 2 Leadscrews 6 35mm diameter x 1mm pitch Spindle to table 200mm 8 Spindle to column 55mm 2 1 4 Throat 87mm 3 1 2 Spindle bore 10mm 1 2 Spindle nose thread 3 4 16 TPI Spindle taper 1 Morse Spindle speed 0 3000 rpm programmable Machine resolution 0 01mm 0 0004 Dimensions Machine length 686mm 27 Machine depth 648mm 26 1 2 Machine height 686mm 27 Weights Machine weight 70 KG 154 lb Electrical Details Mains supply required 1 Phase 220 240 Volts 8 Amps 50 60 Hz Spindle motor 1 5 HP 1 1Kw Axis stepper motors 200 steps rev AC servo max torque 11Nm LoVo light 110 Volts AC Micromill CNC Milling Machine User s Manual Section 15 Appendix 95 15 What is a Part Program 96 Appendix Section 15 A Part Program is a list of coded instructions which describes how the designed component or part will be manufactured This part program is also called the CNC File These coded instructions are called data a series of letters and numbers The part program includes all the geometrical and technological data to perform the required machine functions and movements to manufacture the part The part program can be further broken down into separate lines of data each line describing a particular set of machining operations These line
42. arting the software esssssesersrirrr 29 Switching on and Off cesses 28 Microswitches column cross slide table we ssi Miteebite clamps sssrin 56 Moving the AX S wa 45 0 Offsets configure tool length offset 64 configure workpiece offset cesses 61 create new workpiece offset fle 62 move to tool offset reference 2009 move to workpiece datum an 61 OVEIVIEW sssi Micromill CNC Milling Machine User s Manual 17 Index P Part program composition example sssri 97 what is a part program oo eee 96 PC connections to your Micromill isss 19 PC Specifications required secere 23 Potentiometer Controls issiria 69 Protective coatings removal cseseseeeeeees 21 Q Quick Change tooling occ 49 R Removal of protective coatings e 21 Removing a tool drawbar system sss 47 Running a CNC file auto Mode eset 67 S Safety emergency stop button features seiis interlock guard switch precautions n s SAVING a GNGC file sce ccessivscvgessststennasscccaiansiectans Simulation Siting your Micromill oes ees tessteeseeesteeseesees 17 Slideways lubrication sses 76 Software AUTO MODE anaota 67 Changing COM Ports sssrin 90 co ordinate display modes 42 general layout 30 NOME MOE iaiia 41 introduction jog mode override feedrates and spindle speeds starting Specification of Micromill Spindle drive belt adjustment Spindle drive board sessen Spindle sp
43. ase motor bolt 2 Turn anticlockwise to release or clockwise to tighten the bolts holding the spindle drive motor in position when directly viewing the face of the bolt from beneath the bracket Micromill CNC Milling Machine User s Manual Section 13 Maintenance 87 14 Technical Support Denford Limited provides unlimited telephone Technical Support on this CNC machine to registered users On site visits by our engineers may be chargeable Please refer to the information held in your separate Warranty pack for specific details Before contacting Denford for support please read your hardware and software manuals and check the FAQ section on our website When you request support please be at your CNC machine with your hardware and software documentation to hand To minimise delay please be prepared to provide the following information e CNC Machine Serial Number e Registered user s name company name The controller software name and version number found in the Help About menu e The wording of any error messages that appear on your computer screen if applicable e A list of the steps that were taken to lead up to the problem e A listof any maintenance work that has been carried out on the CNC machine Contact Details Denford Limited Birds Royd Brighouse West Yorkshire HD6 LNB UK Telephone 01484 712264 Fax 01484 722160 ISDN 01484401157 01484401161 E mail service denford co uk Technical
44. bearings Oil optional vice slideways Bi annually e Check the condition of any electrical connections eCheck and clean tooling collets eCheck all cables for kinks and breaks eCheck and adjust spindle drive belt Clean the 3 axis datum microswitches Annually e Check the slides for wear eCheck and adjust gib strips Note Cal X If your CNC machine is used intensively we recommend that the maintenance tasks listed in the above schedule are performed on a more regular basis Lubrication Chart Lubrication Point Lubricating System Frequency Recommended Oil Quantity Slide ways Pump action As required Light Machine Oil such as As required Leadscrews amp oil can 3 in 1 or WD40 Thrust Bearings The bearings in the machine head are lifetime lubricated bearings therefore require no periodic lubrication Micromill CNC Milling Machine User s Manual Section 13 Maintenance 71 13 Lubrication Areas on the Micromill The following items on the machine should be oiled daily using a light machine oil A Slideways B Leadscrews C Thrust bearings The photo below labels each area which requires daily lubrication Your mill is encased in a cabinet For illustration purposes this photo shows a view of the mill column and slideways without the cabinet Spindle Drive Motor Z Axis Thrust Bearing Column Z Leadscr
45. can be changed by the user Remember that the default password listed here will not be recognised if you have changed it If you change any passwords we recommend you make a note of them in the Notes section at the back of this manual 90 Technical Support Section 14 The COM port setting in the VR CNC Milling software must match the COM port being used by your Micromill CNC machine Follow these steps to change the COM port assignment in the software 1 Startthe VR CNC Milling software 2 Click Setup Setup Machine Parameters 3 You may be required to enter a password The default password is denny Type the password and click OK 4 The Machine Properties window will open Double click the Micromill listing 5 Click the Communications listing 6 Change the COM Port setting to match the number of the COM port being used by your CNC machine RS 232 cable then click OK Machine Properties Editor E MILLERS Communications 2 Router s Baud rat 19200 B a MicroMill S es Post Process Com Port al Material Mint File MicroMill mnt Home Polling Delay 50 WP Feed Spindle taahi J Reference Data for Communications JE Machine Capability aot Listing i Tool Change Auto Tool Change ommunications T Input Output Devices Baud Rate Integer value defining the communications Baudrate used to link to M M3 the Motion Controller M M5 is i Com Port Integer value defini
46. chine control software Features available in the VR CNC Milling software package include e Full MDI CNC file editing e 2 Dimensional graphical simulation of CNC files 3 Dimensional graphical simulation of CNC files Comprehensive Tooling features e Full offline control of a CNC machine using Virtual Reality e Full online control of a CNC machine e Context sensitive online help including help with G and M code Programming and CNC file structure J argon Buster Context Sensitive is when the type of input signal of an event automatically changes the output signal MDI refers to Manual Data Input the entering of data by manual means rather than transferral by CD ROM or floppy disk Virtual R eality is a fully interactive three dimensional computer based simulation of a real world object or event Micromill CNC Milling Machine User s Manual Section 1 Introduction 11 1 Before Installing Before beginning to setup your Micromill CNC machine take a moment to check your separate order documentation making sure that all items have been delivered to your establishment Any missing or damaged items should be reported to Denford Customer Services as soon as possible The following equipment is supplied as standard with your Micromill CNC machine The standard egiupment listed here is Micromill CNC machine Note that the precise specification of correct at the time of your Micromill will depend on any opt
47. ckmark indicates datum offset file currently graphic in use button Highlighted workpiece machine offset file Workpiece machine offset file currently in Machine Offset Default Machine Offset use Simulation Offset Default Machine Offset Click on the squares to expand the Machine Offsets list or the Squares to collapse an open list To highlight a machine offset click on its title The co ordinate display panel to the right of the Machine Offsets list shows the X Y and Z co ordinates assigned to the highlighted machine offset A red tick mark is used to indicate the active currently used machine offset also shown in the statusbar positioned at the bottom of the Work Piece Offsets window To create a new Workpiece Machine Offset file 1 Highlight the current machine offset then click the right mouse button on its title to display a pop up menu Highlight and click the Add Offset option from the pop up menu 2 The new offset is always added to the bottom of the machine offsets list with all co ordinate values set to zero Highlight the New Offset then click the right mouse button on its title to display a pop up menu Highlight and click the Make Current option from the pop up menu This configures the New Offset as the currently active machine offset ie the offset file used by the CNC machine Micromill CNC Milling Machine User s Manual 11 Configuring a Workpiece Offset To t
48. ction of material such as a piece of flat Steel bar Press the steel bar firmly against the front edge of the table and adjust the datum plate so its front face also touches the surface of the steel bar Tighten the allen headed bolts Note that although this method is quick itis also fairly inaccurate Flat piece of steel bar Datum Plate Setting Method 2 Datum Plate Machine Table Engineers Square To obtain a better degree of accuracy use an engineers square lined up against the front edge of the machine table Adjust the datum plate so it touches the engineers square and tighten the allen headed bolts This method has the added advantage of allowing the datum plate to be fixed further into the middle of the machine table Micromill CNC Milling Machine User s Manual Section 10 Work Holding 53 10 Setting the Datum Plate Datum Plate Setting Method 3 Machine Table Datum Plate Set up the machine so a pointer is held in place of the cutting tool Align the pointing tool so itis positioned slightly above one of the 2 edges of the datum plate which run parallel with the Y axis Start with the pointer near the back of the datum plate edge you have chosen Move the pointer towards the front of the datum plate checking that the tip of the pointer is still lined up exactly over the edge you have chosen Ifthe pointer does not align readjust the position of the datum plate Keep repeating these steps mov
49. datum defines the zero point for the three dimensional co ordinate grid system used by the machine What are offsets Offsets are a collection of numerical values used to describe the ocation of the workpiece datum Two types of offset file are used in combination to describe this location i The workpiece offset file This file allows global offset values to be set for the X Y and Z axes In other words every tool profile will use the workpiece offset values ii The tool length offset files Every tool has its own individual tool length offset file containing a single Z offset value They are used to compensate for the differences in length between tools How is an offset calculated The X position of the workpiece datum is defined by the value entered into the X dialogue box of the workpiece offset file The Y position of the workpiece datum is defined by the value entered into the Y dialogue box of the workpiece offset file The Z position of the workpiece datum is defined by the combination of the value entered into the Z dialogue box of the workpiece offset file and the value entered into the dialogue box of the tool length offset file that belongs to the tool profile currently in use How is the workpiece datum used The machine controlling software uses the workpiece datum as the starting point zero reference for any co ordinate movements it receives These co ordinate movements are read from our loaded C
50. dialogue box by default but feel free to change it if necessary 2 Confirm and set the Tool Length Offset Value Click the OK button to confirm the value and close the Set Offset window This completes the tool length offset process for the profile currently held in the machine head 3 Repeat the Tool Length Offset process for the next tool profile Place the next tool profile in the machine head Align this tool against the tool offset reference position then specify and confirm the tool length offset values as described in 1 and 2 Repeat the tool length offset process for all remaining tool profiles Note It is important that all tools are configured against the same tool offset reference position 66 Configuring Offsets Section 11 Micromill CNC Milling Machine User s Manual 12 Manufacturing your Part Auto Mode Safety First T X A Never open the safety guard door during the machining process The spindle will not switch off when the Stop button on the File Control toolbar is clicked The spindle will switch off when the emergency stop button is pressed Before beginning to manufacture your part check to see that the following tasks have been completed Billet mounted and secure Tools prepared and numbered ready for use according to your CNC file Safety guard door closed and machine switched on CNC file loaded and checked via simulation Offset files configured or lo
51. displayed as shown below J og Step In jog step mode the selected machine axis will move one increment displayed in the jog control value window each time the selected axis jog key is pressed The slider bar can be moved to set jog increments of 0 01 0 1 0 5 1 5 and 10 units When J og Step is active the J og button graphic will be displayed as shown below 8 Selecting M Codes Ph M Codes M 3 Spindle Forward M 5 Spindle Stop Tax M codes are used for the following miscellaneous functions Ifthe M code you M3 Switch spindle on require is not displayed M5 Switch spindle off in the dropdown list i enter the M code in a To access the list of M codes click the J og tab on the Machine blank Editor window Mode window Run the singl l aA Click the M Codes button to display the list of available clicking the Auto tab miscellaneous machine functions Highlight and click on the on the Machine Mode required M code window followed by the adj L Play button on the For detailed information regarding M code Programming click Help File Control toolbar CNC Programming to display the Denford CNC Programming for Milling Machines helpfile 44 CNC Machine Control Section 8 Micromill CNC Milling Machine User s Manual 8 J ogging the Axes Movement Keys Moving the Axes Six keys on your computer keyboard are used to manually jog move the CNC
52. dy for use with the CNC machine To display the Machine Tooling window click the WS Tooling button shown right from the Options j toolbar Tooling General Layout of the Machine Tooling window A black coloured number indicates the absence of any tool profile When a tool is transferred from the Tooling Library window to the Machine Tooling window the colour allocated to that tool profile is also transferred These colours associated are applied to the tool numbers as they become filled Tools should be placed in numbers according to the number definitions defined in the CNC file being used For example if your CNC file defines T02 as a 2 0mm slot cutter then a 2 0mm slot cutter must be transferred to number 2 in the Machine Tooling window The triangular red marker arrow indicates the tool currently held in the machine head In the example below tool number 1 is currently held in the machine head The data panel in the centre of the window relates to the tool number indicated by the grey pointer In the example below the data panel relates to tool number 2 a 2 0mm slot cutter To close the Machine Tooling window click the Tooling button from the Options toolbar Machine Tooling e Window Titlebar Triangular Red Marker currently held tool Tool Data Panel Marker T 2 Details 2mm Slot Drill Tool Type Slot Mill Tool Data Panel Tool Diameter 2 000 Tool Length 50 000 Tool Flute L
53. e Windows clipboard CTRL C will copy any highlighted text from the Editor window to the Windows clipboard CTRL P will place any text held in the Windows clipboard to the current Editor window cursor position describing the programmed sequence of commands and movements used to manufacture the part Hence CNC files are often referred to as Part Programs The Editor itself behaves in a similar way to a simple word processor such as Windows Notepad Click the mouse cursor inside the Editor window then begin typing in or editing the text from your CNC file When each line of text is completed press the Enter Return key to create a new program line G21 BILLET X60 Y60 Z2 EDGEMOVE X0 YO TOOLDEF T1 D4 TOOLDEF T2 D2 G91 G28 X0 YO zol Line 6 Column 17 CNC Programming Basics CNC files are constructed using G and M codes Each line of G and M codes is called a block for example G91 G28 X0 Y0 Z0 from the part program shown above Each block is created from different program words for example G91 is one word from the part program shown above Each program word is constructed from a letter called the address and a number The address letter together with its number describes the type of code used For more information about using G and M codes click Help CNC Programming to display the CNC Programming helpfile containing sections on part program structure and
54. e Z ce 2 axis i i Change the tool in the machine to Tool Number 1 F Cancel Teea Always waitfor the spindle and machine axes to stop moving before attempting to open the safety guard door A Replace the current tool number with the tool number specified in Tere ri the message window the tool profiles allocated to each tool number the working area when are listed at the beginning of your CNC program the spindle or machine Close the safety guard door and click on the OK button to resume AXES Are MONY your machining Micromill CNC Milling Machine User s Manual Section 9 P reparing Tooling Hardware 51 10 The Datum Plate The Datum Plate is an L shaped bracket used for locating work to a precise position on the machine table Itis fixed in position using two Tee nuts that are tightened using allen headed bolts The tee nuts are located in each of the two upside down T shaped channels that run horizontally ie parallel to the X axis under the surface of the machine table Allen headed bolt Tee nut Datum Plate L shaped work locating bracket To loosen bolts turn anticlockwise viewed from above To tighten bolts turn clockwise viewed from above Removal of Datum Plate To remove the datum plate loosen the 2 allen headed bolts by turning them in an anticlockwise direction Slide the datum plate along the machine table until the Tee nuts are released from their channels t
55. e transparent guard window and the computer being used as the controller unit which should be angled towards the user as shown in the diagram below Computer desk monitor keyboard and mouse angled Denford Micromill CNC towards O perator Milling Machine Machine Operator Plan View showing Ideal Machine Operating Positions Micromill CNC Milling Machine User s Manual Section 3 CNC Machine and Software Installation 17 3 Levelling your Micromill Your Micromill should rest level on the two hollow sections which run beneath the machine cabinet The machine itself has been levelled to the machine cabinet prior to dispatch so itis only necessary to level your Micromill to the table on which itis to be situated If you find that your Micromill is not stable resting on these two hollow sections insert four anti vibration pads under the sections at each corner of the machine as illustrated in the diagram below Adjust the pads until the machine is stable and level The pads will also help to reduce the amount of noise and vibration generated when the machine is operating Itis important to remember that the pads are ONLY used to help Stabilise the machine The main weight of the machine should still be taken by the hollow sections i e these sections should ALWAYS be in direct contact with the table surface Anti vibration pads can be fitted on the machine Turn the nut on the pad anti clockwise
56. eed override sesser Standard equipment Starting the software Sub tables sssi Switching your Micromill on and Off siii Micromill CNC Milling Machine User s Manual T Technical support sssri 88 Thrust bearings lubrication we 19 Tool data panel wn 34 Tool length offset wee 64 Tool library WINdOW sssssccccccsssnsriiii 33 Tooling adding new tool profiles sssr 35 drawbar system components aa 46 installing a tool drawbar system 48 machine tooling window aa 36 quick change tooling system we 49 removing a tool drawbar system esse 47 software procedure for tool changing 50 tool data panel w tool library WINdOW ssssssssssiiiiiis 33 Troubleshooting essesi 89 U Unpacking your Micromill sesers 16 Using your Micromill overview neses 25 W Warning notices sesissieccestreernunsvescitarvesrcauidelecturee 6 What is CNC sss 10 Workpiece datum sal Workpiece offsets sssscccssssssnsni 61 Section 17 Index 111 17 Notes Use this page to make a note of any parts of the software you have changed or configured for example common tooling set ups machine parameters changes to installation paths or passwords etc 112 Index Section 17 Micromill CNC Milling Machine User s Manual
57. eeseesstesstesstesstecsteeseeseesees 38 SD SIMULATION eecissscvsvesscccsverscrgenivecscenevsctgoviane 39 COM port SCt Up eisian 90 Connecting schematic diagram showing connections 22 the MAINS Supply oseese 20 the PC to the Micromill sssri 19 Contact information oo 2 Contents isses a3 Conventions used in manual sesers 8 D Datum microswitches cleaning eee 81 Datum plate removal and fitting sssr 52 setting methods Denford directives list sssrinin 101 Denstep motion control board oo eee 92 Disclaimer Drawbar tooling system Micromill CNC Milling Machine User s Manual E EC declaration of conformity secese 103 Editor WINdOW asenin aaan 32 Electronics denstep motion control board sses 92 inside the control box 91 spindle drive board wees 93 Emergency Stop button oo 14 F FAQS inuina 89 Feedrate override oe eeeesecseeseessesstesseesseesseenees 69 G G codes USE cssieettucedietelidecletsdeeudhlenietaludtiveteds 98 Gib strip adjustment on X axis adjustment on Y axis adjustment on Z axis general sss n S a E E E EER H Help technical support oo cece 88 HOMO ModE bisean a 41 Homing the machine sssr 41 l Installation before you start s ssssssssssrsrsrsrsrsrssssssssesesesesss 12 VR CNC milling software sses 24 Installing a tool drawbar system sss 48 Interlock guard SWItCH ssssssisisisiririrrrrrrrrrsrersrss 15 Introduction Micromill esnin aa 9 VR CNC milling s
58. ency stop button Totally enclosed guard door with interlock switch Electronic shear key built into spindle controller Option on control software to check CNC programs prior to machining Safety Precautions Safety is very important when working with all forms of machinery but particularly when working with CNC equipment due to the hazardous voltages speeds and forces that exist in the hardware Follow the rules below at all times when using your Micromill CNC machine General Safety Precautions Wear clothing suitable for machine operation and follow the safe working procedures in place at your establishment Do not place any objects so that they interfere with the guards or the operation of the machine Never try to clean the machine if any part of it is rotating or in motion Always secure the work on the table or in a fixture or vice Ensure that the correct cable for the power source is used Ensure the mains power is switched off and preferably unplugged before starting any maintenance work on the machine Posta notice informing others not to use the machine since it is undergoing maintenance If power fails turn off the mains power switch immediately and unplug the machine from the mains power socket Hazardous voltages can still exist immediately after switching the machine off Always wait at least 5 minutes before removing the rear cover to access the electrical panel Lubricate the required machine areas at the i
59. ength 25 000 Tool Flute Count 2 Maximum Tool Life 50 Current Tool Life 0 Tool Length Offset 0 000 Too Number Current Filename Default mtf Machine Tooling Filename Micromill CNC Milling Machine User s Manual Tools can also be dragged from the tooling lists in the Tooling Library window and dropped into the appropriate number Slots in the Machine Tooling window Deleting Tools from the Machine Tooling window Click the right mouse button on the number of the tool you want to remove then highlight and click the Remove Tool option on the pop up menu The tool number will change to a black colour to indicate it is empty Machine Tooling Edit Tool Data Change Tool Type gt Change To This Tool Remo ool Move Tool To Swap Tool with Insert Tool Current Filename Default mtf Adding Tools into the Machine Tooling window Click the right mouse button on the empty black tool number in the Machine Tooling window Highlight and click the Insert Tool option on the pop up menu then highlight and click on the title of the tool you want to add The selected tool will then be allocated to the specified tool number Machine Tooling awoke Edit Tool Data Change Tool Type Set Z offset for this Tool Remove Tool Move Tool To gt Swap Tool with Insert Tool 2mm Slot Drill 4mm Slot Drill 1 8 0 125 Slot Drill 3 16 0 1875 Slot Drill C
60. es regarding this CNC machine without notice or documentation 6 Contents Micromill CNC Milling Machine User s Manual About this Manual Using this manual This manual provides information describing how to transport site Disclaimer Screenshots Language Contact Updates setup and operate the basic functions of your Denford Micromill CNC machine including any operational features of hardware specific to the Micromill series A Routine Maintenance section is also included More detailed information regarding the Virtual Reality CNC Milling software used for controlling your Micromill is contained in the separate VR CNC Milling Software User s Manual supplied with your machine Please note that the Electrical Diagrams for your Micromill CNC machine are not included in this manual they are delivered separately in the standard equipment box supplied with your Micromill CNC machine If you have any doubts and or questions regarding the specification servicing or features of your machine please contact Denford Customer Services Denford Limited reserves the right to change the specification and or operating features regarding this CNC machine without notice or documentation We take great pride in the accuracy of information given in this manual but due to nature of hardware and software developments be aware that specifications and features of this product can change without notice No liability can be accepted
61. et of MDF is used as a sub table This MDF is clamped down and used as a Safety measure to prevent damage occurring to the machine table itself should a problem occur when milling Miteebite clamp KKA shown in closed A position Machine Datum Sub table Miteebite table plate eg sheet clamp of MDF Loading the Billet The actual workpiece such as a sheet of plastic would be held in place on the sub table using double sided tape The billet is usually positioned with its front and lefthand edges aligned with the front and lefthand edges of the sub table as shown below Plastic workpiece billet Strips of double sided tape Sub table eg sheet of MDF Towards front of machine table l 56 Work Holding Section 10 Micromill CNC Milling Machine User s Manual 10 How does a Miteebite Clamp work The base of the Miteebite clamp consists of a Tee nut with 2 threaded holes passing right through its section from top to bottom One of these threaded holes contains a grubscrew When this is tightened the base of the grubscrew pushes against the surface of the T channel in which it has been placed securing the Tee nut in position The other threaded hole contains a bolt which has its head and allen key hole machined slightly off centre A hexagon washer spins freely around this bolt head The bolt behaves in a similar way to a cam when rotated If the allen key hole is facing away from the grubscrew t
62. ew Machine Head behind column Column Z Cross Slide Y Slideway Leadscrew Y Axis Saddle under Thrust machine table Bearing Cross Y Slideway Table Table X Column Table X X Axis Leadscrew Base Slideway Thrust under table Bearing 72 Maintenance Section 13 Micromill CNC Milling Machine User s Manual 13 Lubrication of Leadscrews Table X Axis Leadscrew Lubrication Run the machine table fully to the right to gain access to the table Slide leadscrew The leadscrew is located under the machine table Pump oil directly onto the exposed surface of the leadscrew Run the saddle fully to the left to gain access to the opposite end of the leadscrew Pump oil directly onto the remaining surface of the leadscrew Finally run the table left and right along the X axis to distribute the oil along the full length of the leadscrew Location aX Look under table Pump oil along the leadscrew arrowed Micromill CNC Milling Machine User s Manual Section 13 Maintenance 73 13 Lubrication of Leadscrews Cross Slide Y Axis Leadscrew Lubrication Run the saddle back towards the machine column to gain access to the front section of the cross slide leadscrew Pump oil directly onto the exposed surface of the leadscrew Run the saddle forwards to gain access to the opposite end of the cross Slide leadscrew Pump oil directly onto the remaining surface of the leadscrew
63. fting precautions in accordance with Health and Safety Regulations in your establishment Ensure that your Micromill is both secure and balanced before lifting To transport your Micromill over longer distances use a suitably sized trolley DataPanel EaimJEg Lifting Data Micromill CNC machine weight 70 KG 154 Ib Lifting points identical lifting points at opposite side panel 16 CNC Machine and Software Installation Section 3 Micromill CNC Milling Machine User s Manual 3 Deciding on a Site for your Micromill DataPanel EiimJeg Dimensional Data Machine length 686mm 27 Machine depth 648mm 26 1 2 Machine height 686mm 27 Remember when positioning the machine in the room space will be required for opening of the electrical control box door We recommend you leave a gap of atleast 1 9Gmm A 388mm clearance must also be left at the rear of your Micromill This space will be occupied by the safety guard when in its fully opened position Sufficient room should also be provided for effective maintenance to be carried out around the machine itself The Micromill is a bench mounted machine so it should be sited on a bench of sturdy construction to take the weight of the machine and of a height which enables comfortable operating and programming to take place Ideally the user will operate the machine when standing at its front with a clear view of both the machine table through th
64. g to the line being executed in the CNC file until the end of the CNC file is reached The main area of the 2D Simulation window depicts a full plan view of the billet The narrow righthand column of the 2D Simulation window depicts the billet side view used for indicating tool cutting depths 2D Simulation x 5 000 Y 55000 2Z 2000 Tool 2 Micromill CNC Milling Machine User s Manual 7 Running a 3D Simulation of a CNC File o Se The 3D Simulation window provides a three DSD dimensional view of the billet together with a 3D Simulation graphical representation of any machined parts To display the 3D Simulation window click the 3D Simulation button shown above from the Outputs toolbar To close the window click the 3D Simulation button again Click the Use X Y Offsets option on the 3D Viewer menu so a tick mark is not shown next to the title This will display the 3D simulation without using any simulated offsets To run the CNC file ensure the Editor window cursor is positioned Before running the 3D at the start of the first line of the CNC file simulation e Check that the units of measurement Set for the VR CNC Milling software matches the units used in both the ccs TM Jal tooling profiles The The graphics in the 3D Simulation window shown below are units of measurement updated according to the line being executed in the CNC file until the setting for the V
65. g your Micromill CNC machine Congratulations on your purchase of a Micromill series CNC machine In this manual you will learn how to setup and use your Micromill The Micromill is a full three axes CNC training machine Ithas been designed with you in mind making the processes involved both safe and easy to use Main Features Designed specifically for Education and Training e Manufactured to industrial standards e Programming via International Standards Organisation format CE approved for safety Capable of cutting synthetic materials such as wax plastics acrylics and non hardened metals such as aluminium e Links to various CAD CAM software packages Totally enclosed high visibility interlocked guard e Option of Including in FMS CIM systems Micromill CNC Milling Machine User s Manual Section 1 Introduction 9 1 What is CNC 10 Intoduction Section 1 CNC Computer Numerical Control is the general term used for a system which controls the functions of a machine using coded instructions processed by a computer CNC machines are a very important part of the modern manufacturing process Indeed many of the different types of products you use everyday have been made using some sort of CNC machine The CNC Manufacturing Process Example The sequence shown below defines the main steps involved in producing a component using a CNC system 1 A part program is written using G and M codes This
66. he width of the Slide Any excessive movement will indicate that the slide in question requires adjustment To accurately assess the condition of each slide Denford recommends the use of a dial gauge Note that a slight degree of movement will always be present in every slide If there is no free movement whatsoever then the Slides would be too tight to move Micromill CNC Milling Machine User s Manual Section 13 Maintenance 83 13 Gib Strip Adjustment X Axis Gib Strip Adjustment Method 1 Release the gib strip locking screw positioned on the back of the machine saddle shown below Location a X Look at back of machine Turn anticlockwise to release or clockwise to tighten locking screw when viewing the face of the locking screw 1 2 Push the wider end of the gib strip further into its channel to eliminate the free play in the slideway The gib strip is accessed by reached under the machine table see below Remember that a slight degree of movement must be left in the slide to allow the slide to move Location Ja X Look under machine table Locking Screw 3 Tighten the gib strip locking screw 4 Move the machine table left and right across the saddle to ensure that the movement is smooth 5 If the movement is not smooth adjust the gib strip by repeating steps 1 to 3 Run the machine table again to assess the smoothness of movement 84 Maintenance Section 1
67. hen the hexagon washer is slack against the work ie the miteebite is open If the bolt is then turned through 180 degrees so that the allen key hole is now facing towards the grubscrew then the hexagon washer will be tight against the work ie the miteebite is closed Continual turning of the bolt is unnecessary since the full range of movement for the hexagon washer is covered in a single 360 degree rotation of the bolt In this respect the hexagon washer will not tighten further if the bolt is continually turned clockwise Bolt both the head Grub screw and the allen key passes through holes are machined Hexagon the base of the slightly off centre washer Tee nut m To loosen grubscrew _ turn anticlockwise viewed from above To tighten grubscrew turn clockwise viewed from above Tee nut Micromill CNC Milling Machine User s Manual Section 10 Work Holding 57 10 Using Miteebite Clamps The example used in the description below uses a plastic sheet billet held on a temporary MDF sub table using double sided tape Set the Datum Plate into position then place the temporary MDF Sub table onto the machine table so itis located correctly against the edges of the datum plate Next position the miteebites into their respective T channels and Slide them along until they touch the sub table Ensure that one of the six flat sides of the hexagon washers press against the sub table not one of the hexag
68. hen withdraw the datum plate from the machine table Fitting of Datum Plate To fit the datum plate in position on the machine table place it at the end of the T shaped channels Align each Tee nut with its respective channel and slide it into position Slide the datum plate along the machine table to the required position Note that the datum plate can be slightly adjusted forwards and backwards ie parallel to the Y axis if required Once the datum plate has been approximately positioned in the correct place tighten each of the allen headed bolts by turning them in a clockwise direction until they just begin to grip the plate to the table surface It must still be possible to move the datum plate since it may require final adjustments if it needs to be lined up square with respect to the machine axes 52 Work Holding Section 10 Micromill CNC Milling Machine User s Manual 10 Setting the Datum Plate The following diagrams illustrate the various methods that can be used when positioning the datum plate square with respect to the machine table ie the edges of the datum plate run exactly parallel with the X and Y machine axes Each method varies according to the level of position accuracy required Datum Plate Setting Method 1 Datum Plate HE Table SSS This method is useful if the front face of the datum plate can be positioned exactly level with the front edge of the machine table Use the true flat face of a se
69. hine tool JOG CONTROL wee Manual movement mode for the machine axes using very small pre defined movements called jog steps One stepped movement is applied per movement key button press Mi CODE irunia A miscellaneous code function in a CNC program used to indicate an auxiliary function ie coolant on tool change etc MACHINE CODE hss The code obeyed by a computer or microprocessor system with no need for further translation 106 Glossary Section 16 Micromill CNC Milling Machine User s Manual 16 Glossary MACHINE DATUM uw A fixed zero reference point set by the machine manufacturer The machine datum is used to define the co ordinate based grid system of the CNC machine All machining co ordinates originate from this point However this point can be temporarily moved using the machine offset facility MACHINE OFFSET The workpiece offset file used with VR and real CNC machines MACHINE TABLE 0 See table MDI iineoa Manual Data Input A method used for manually inserting data into the control system ie Desktop Tutor qwerty keyboard etc MITEEBITE CLAMP Method of securing work to the machine table using the series of machine table T channels MODAL scdsecsitecoantilcenaieati Modal codes entered into the controller by a CNC program are retained until changed by a code from the same modal group or cancelled Numerical control ORFSET cctieanserccratsrcanes Combination of
70. i Machine Table Machine Table Before you can begin entering the machine offset values you must position the tool over your workpiece datum 64 Configuring Offsets Section 11 Micromill CNC Milling Machine User s Manual 11 Configuring the Tool Length Offset Movement Modes To switch between the two modes of movement click the J og button in the Machine Mode window Use J og Step Continuous for continuous movement when a movement key is pressed and held down The slider bar can be moved to set jog speeds between 0 and 1000 units Use this mode for rough positioning Use Jog Step Mode for a single increment movement each time a movement key is pressed The slider bar can be moved to set jog increments of 0 01 0 1 0 5 1 5 and 10 units Use this mode for precise positioning Micromill CNC Milling Machine User s Manual Move the Tool over the chosen Tool Offset Reference Position Move the Cutter to the chosen Tool Offset Reference position Highlight the Machine Mode window and select the J og tab To move the tool use the six movement keys X Axis Cursor Right or Cursor Left Y Axis Cursor Up or Cursor Down Z Axis Page Up or Page Down Remember the tool and machine table can only be moved when the Machine Mode window is active Move the tool so its cutting tip just touches the tool offset reference position Take care not to damage the cutting tip when
71. ine table can only be moved when the Machine Mode window is active Move the tool so its cutting tip just touches your chosen workpiece datum position Take care not to damage the cutting tip when manoeuvring the tool ae Machine Head Sub table eg sheet Workpiece of MDF Datum O ye Qes Machine e 7 In this example the workpiece datum is set at the front left upper corner of a sub table The CNC file will eventually machine a piece of plastic that will be taped to the sub table Section 11 Configuring Offsets 61 11 Creating a new Workpiece Offset File Notice there are two types of workpiece offset file used in the VR CNC Milling software i The workpiece machine offset files these values are used by any VR or real CNC machines Itis these files that are referred to in this section ii The workpiece simulation offset files these values are only used when simulating an offset with the 2D or 3D graphics 62 Configuring Offsets Section 11 4 To display the Work Piece Offsets window click L the Offsets button shown left from the Options toolbar To close the window click the Offsets button again General Layout of the Work Piece Offsets window Window titlebar E Machine Offsets Default Machine Offset Simulation Offsets Default Simulation Offset Offsets Highlighted machine workpiece offset values Ti
72. ing the pointer forwards and backwards along the datum plate edge until a Suitable degree of accuracy has been obtained For a final check the pointer can be moved above and along one of the datum plate edges which run parallel to the X axis Finally tighten the allen headed bolts to fix the datum plate firmly in place 54 Work Holding Section 10 Micromill CNC Milling Machine User s Manual 10 Setting the Datum Plate Datum Plate Setting Method 4 Machine Table Datum Plate Setup the machine so a dial gauge is held in place of the cutting tool Align the dial gauge so itis positioned along one of the 2 sides of the datum plate which run parallel with the Y axis Start with the dial gauge near the back of the datum plate edge you have chosen Move the dial gauge towards the front of the datum plate checking that the values indicated on the dial gauge do not alter If the values do alter readjust the position of the datum plate until the values are constant Keep repeating these steps moving the dial gauge forwards and backwards along the datum plate edge until a suitable degree of accuracy has been obtained Finally tighten the allen headed bolts to fix the datum plate firmly in place Micromill CNC Milling Machine User s Manual Section 10 Work Holding 55 10 Miteebite Clamps Miteebite clamps are a quick and versatile method of securing most pieces of work to the machine table In the example shown below a she
73. ions selected at the time of printing butis liable to ordering see below change through e Guard Door Interlock Switch torx bit continuous development RS 232 serial link cable SECURING Set of imperial allen hex keys 1 16 5 64 3 32 1 8 5 32 3 16 7 32 1 4 Set of metric allen hex keys 2mm 2 5mm 3mm 4mm 5mm 6mm Spindle Bar Collet 1 4 End Mill 3 16 Drawbar with washer Set of fuses 5x20mm 6 3A 10A 3 15A Micromill CNC machine warranty pack Micromill CNC machine inspection certificate Micromill CNC machine manual this book Virtual Reality CNC Milling Software CD ROM Mousemat Virtual Reality CNC Milling Software manual Machine Commissioning and Basic Instruction 1 Day Training Course for 2 persons at Denford Limited UK The following optional equipment may also be supplied with your Micromill CNC machine please refer to your separate order documentation for confirmation Workholding Vice e Work Holding Package including Datum Plate Miteebite Clamps and Tee Nuts Various Tooling Packages CAD CAM Software Educational Project Books and Courseware Project Material Packages Additional and or On site Training Courses 12 Intoduction Section 1 Micromill CNC Milling Machine User s Manual 2 Safety Features Overview and Precautions Safety Features Overview The following safety features are standard on your Micromill CNC machine Emerg
74. is not lit check the control board fuse The part is being cut at an incorrect depth Check the validity of the following 1 The Z value entered in the tool length offset 2 The Z value entered in the workpiece offset file 3 The number size used for defining the depth of cut used in your CNC program 4 The sign or used for defining the depth of cut used in your CNC program If your workpiece datum is aligned with the upper surface of your billet any Z values cutting into this billet will have a minus sign The machine begins cutting the part at the wrong location Check the X and Y values entered in the workpiece offset file When using double sided tape the billet keeps lifting from the sub table sheet of MDF Check the surface of the sub table is clean and smooth before attempting to add the billet Routinely clean tape adhesive residue from the sub table Check tape adequately covers all parts of the billet Check the sequence in which the various parts of your design are machined For example machine any small or etched surfaces before cutting pieces completely out from the billet If you keep the largest solid area of the billet attached to the sub table for as long as possible you reduce the likelihood of the billet moving during machining Micromill CNC Milling Machine User s Manual Section 14 Technical Support 89 14 Changing COM Ports The password used to access the Machine Properties window
75. layed Click the OK button to continue 3 Click the Stop button on the File Control toolbar 4 If required click the Rewind to start button to move the cursor in the Editor window back to the beginning of the CNC file 5 Click the Home tab in the Machine Mode window then home all three the machine axes 6 Click the Auto tab in the Machine Mode window then click the Play button on the File Control toolbar to restart the machining process O If the Stop button on the File Control toolbar is used to stop the machining process 1 The spindle will not switch off when using the Stop button To Switch off the spindle click the og tab in the Machine Mode window then click the M Codes button Highlight and click the Spindle Stop option from the pop up menu 2 If required click the Rewind to start button to move the cursor in the Editor window back to the beginning of the CNC file 3 Click the Home tab in the Machine Mode window then home all three the machine axes 4 Click the Auto tab in the Machine Mode window then click the Play button on the File Control toolbar to restart the machining process 68 Part Manufacture Section 12 Micromill CNC Milling Machine User s Manual 12 Overriding Feedrates and Spindle Speeds Using Potentiometer Controls OVERRIDE FEEDRATE SPINDLE I The left side of the front panel when viewed from the front of the machine co
76. le program or G and M code program A G and M code is a series of letters and numbers that make up the language used by CNC machinery Micromill CNC Milling Machine User s Manual 1 What is the VR CNC Milling software Virtual Reality VR CNC Milling is a Windows based software package allowing full editing and control of CNC files The term Virtual Reality stems from the ability to control a Virtual CNC machine in the software In other words the computer can create an exact replica of the Micromill which is fully controllable just like the real machine We call this software mode Offline meaning we re working away from the production line Similarly Online means we re using the software to directly control the operation of a real Micromill CNC machine connected to your computer Information is accessed and displayed using an interface similar to other popular Windows based software applications The familiar dropdown menus toolbars and software display windows can be configured to suit the level and requirements of each user Since the software supports full offline facilities it allows many training tasks such as setting tool offsets to be carried out away from the CNC machine itself Options such as these allow groups of students to work simultaneously whilst helping to free valuable CNC machine resources The same interface is used online allowing students to produce their designs without having to learn any new CNC ma
77. ll CNC machine 1 Ensure the RS232 lead is fitted securely between the PC being used to control the CNC machine and the RS 232 socket at the back of the right end Micromill side panel 2 Check the electrical panel access door at the rear of the CNC machine door is securely fastened 3 Plug the mains supply cable from the CNC machine into an available power socket Switch the power socket on 4 Turn the keyswitch mounted in the middle of the Micromill front panel one quarter clockwise to its on position 5 Press the circular red power button to the right of the keyswitch The light inside the button will illuminate and you should hear the Micromill begin its power up routine If the Micromill does not power up turn the keyswitch to its off position When power is cut to the CNC machine the light on the circular red power button should also disappear Switch off the power at the mains socket Check all connections and fuses to see that proper power and communication is established to the CNC machine If you need to access the electrical panel at the rear of the CNC machine wait at least 5 minutes before attempting to open the access plate Hazardous voltages can still exist immediately after Switching off the power To switch on the Micromill A Turn the keyswitch mounted in the middle of the front panel one quarter turn clockwise B Press the circular red power button In the diagram opposite the Keyswitch is
78. ly Restart your computer before trying to run the VR CNC Milling software for the first time 3 4 5 6 7 8 It is recommended that Important you allow the Denford Once the software has installation program to been installed we create its own recommend you place directories and set up its any software master default values If you copies in a safe dry find these inconvenient location then feel free to alter them 24 CNC Machine and Software Installation Section 3 Micromill CNC Milling Machine User s Manual 4 Using your Micromill Overview Several steps must be completed before the final manufacture of a part The flowchart below lists the general steps that should be followed for CNC file creation simulation and final part manufacture in the recommended order However miscellaneous factors may warrant the user to complete the steps in a different order to that shown XH A Switch on the Micromill and start the VR CNC Milling software For more detailed see section 4 pages 26 to 27 information regarding these steps please refer to your separate VR 5 CNC Miling Software B Load or create the CNC program User s Manual see section 5 pages 31 to 32 HEE C Configure the tooling in the VR CNC Milling software Steps F and G are not ad when working see section 6 pages 33 to 37 with a Virtual R eality CNC machine Billet data is taken from D Simulate the CNC program in 2D
79. machine axes To move the X machine axis use the Left Cursor and Right Cursor arrow keys with the Machine Mode window active To move the Y machine axis use the Up Cursor and Down Cursor arrow keys with the Machine Mode window active To move the Z machine axis use the Page Up and Page Down keys with the Machine Mode window active In order to move any of the machine axes the Jog panel of the Machine Mode window must be active ie the titlebar is highlighted and the words Jog are highlighted in green Page Down gt Left Cursor Micromill CNC Milling Machine User s Manual Section 8 CNC Machine Control 45 9 The Drawbar and Collet Tooling System Diagram showing layout of the standard Drawbar and Collet Tooling System components Drawbar Collet Components Drawbar S Drawbar Washer ae Collet Cutting Tool 46 Preparing Tooling Hardware Section 9 Drawbar Collet Assembled Drawbar Washer Drawbar Collet Cutting Tool Drawbar Collet Fitting Tools I2 Spanner Spindle Bar Micromill CNC Milling Machine User s Manual 9 Removing a Tool from the Drawbar Collet Removing a Tool 1 Place a soft cloth under the spindle incase the tool unexpectedly falls out of the collet during the operation Move the machine head approximately halfway down the Z axis to all
80. name to be called as a subprogram Example SUBPROGRAM 0209 FRED M98 PO20B This example assigns a subprogram number of 20 to the program named FRED then calls the subprogram 0209 TOOLDEF This directive sets the length and diameter of a cutting tool The length of a tool is the distance from the spindle nose to the bottom of the cutter Example G21 ITOOLDEF T1 D8 Z65 This example defines tool number 1 as being 8mm in diameter and 65mm long continued Micromill CNC Milling Machine User s Manual Section 15 Appendix 101 15 Denford Directives STEP This directive runs an on screen program in single steps This means the program will run one program line then wait for the operator to prompt it to move to the next line this continues until the program is instructed to stop this function The directive applies to both simulation and actual machining with a program NO STEP This directive runs an on screen program without single steps This means the program will run as originally intended with no pausing unless a pause is requested from within the program itself The directive applies to both simulation and actual machining with a program SHOW This directive allows the machining operations to be graphically simulated on screen INOSHOW This directive stops the machining operations from being graphically Simulated on screen 102 Appendix Section 15 Micromill CNC Milling Machine User
81. ng G and M codes also called the CNC program CUTTER SPEED sses The velocity of the cutting edge of the tool relative to the workpiece With circular tools the cutting speed is related to the tool when new maximum cutting diameter Usually the effect of feedrate is ignored CYCLE ssania A sequence of events or commands DATUM cepin The point co ordinate from which a series of measurements are taken DATUM PLATE wees The L shaped bracket used to help locate pieces of work in position on the machine table DESKTOP TUTOR The input control keypad for the machine Keypad overlays are interchangeable according to the type of controller required Micromill CNC Milling Machine User s Manual Section 16 Glossary 105 16 Glossary DIRECTORY sa wsiivcivivescve An area of a disk containing the names and locations of the files it currently holds DISK iaeitinasiticaiiiiva A computer information storage device examples C drive is usually the computers hard internal disk and A drive is usually the floppy portable 3 5 diskette disk DRIVE The controller unit for a disk system DRY RUN iait An operation used to test how a CNC program will function without driving the machine itself DWELE Aria A programmed time delay EDITA ai an The mode used for altering the content of a CNC program via the Desktop Tutor or qwerty keyboard END OF BLOCK SIGNAL The symbol or indicator that defines the end of a block of data
82. ng the RS232 ae i ae cana esi COM serial Portnumber used to link the a Triac Motion Controller Hardware resources IRQ etc are those specified in Windows Control Panel Mint File Integer value defining the name and location of the Mint file MNT file that is to be sent to the Motion Controller Polling Delay Boolean value defining the delay in multiples of 15ms between each command sent to the motion controller Change Password Micromill CNC Milling Machine User s Manual 14 Electronics The photo below labels all important areas of your Micromill CNC machine s electronics contained in the electrical control box Please note that the configuration for your electrical control box may differ from the photo depending on components and options fitted to your Micromill Micromill Electronics Panel Layout Denstep Motion Control Board Mains Main 24V Terminals Fuse Power Rack Supply The Electrica for your Micro Relay Modules Diagrams mill CNC machine are not included in thi s manual They are delivered separately in the standard equi supplied with pment box your Micromill CNC machine Further electri cal schematics are available on request Micromill CNC Milling Machine User s Manual Spindle Drive Board Ferrite Core Control Transformer Section 14 Technical Support 91 14 Electronics The Denstep Motion Control Boa
83. nnnnininin 30 Section 5 Loading or Creating a CNC File Loading and Saving a CNC File ssssssssssssssssssssssssstereieiersreiniesnsnsnsnsrsnsnnnssssnnnnnnens 31 Mhe Editor WINDOWS Sai eit t Reads dient eases has 32 Micromill CNC Milling Machine User s Manual Contents 3 Contents 4 Contents Section 6 Configuring Tools in the Software Using the Tool Libra yerinin aaa A A 33 Viewing Tool Data As Adding NeW Tool P TOTES eisenii aaa E 35 Using the Machine Tooling WiINdOW ssssssssssssssssssssssssssssttsrirntntnritntntnrnrnrnnennnnsnnnnnnnnns 36 Transferring Tools into Machine Tooling esssccccccccncccnerinnnnnnsnns 37 Section 7 Simulating a CNC File Running a 2D Simulation of a CNC File sssssssssssssssssssssrsrsrsrsriririrsrsrerererereresnsesesens 38 Running a 3D Simulation of a CNC File ssssssssssssssssssssssssrsrsrsrsrirsrererererernrernsnsnsnsesns 39 Section 8 CNC Machine Control Machine Communications ssetessseesstesssseecsssessteesssecssseessteesseesssseesstecseressnseenseessees 40 Homing the CNC Machine Home Mode sssssssssssssssssssssssssssssriririririririrnrererererereresns 41 Co ordinate System Display Modes cesseeseeseeseesesseesseessecsseesseseseeneesneesneesees 42 J ogging the Axes J og Mode 43 Selecting M Codes wees Ad Jogging the Axes Movement Keys n ssssssssssssssssssssrstststststntnttttttttininititntnterernrnrerenns 45 Section 9 Preparing Tooling Hardware The Drawb
84. nnnnnanrnnrnne 8 Section 1 Introduction Introducing your Micromill CNC machine a9 Whats ENG ioiii What is the VR CNC Milling software Before Installing n a a aa a 12 Section 2 Safety Features Safety Features Overview and Precautions oo 13 Safety Features Emergency Stop Button wl Safety Features Interlock Guard Switch oo ceseeeeseeseesseesseesseeseesseeseesseesneesneenees 15 Section 3 Machine and Software Installation Unpacking amp Lifting your Micromill c cescessesseeseeseeseeseesseesseeseessecssecsseesneernesaes 16 Deciding on a Site for your Micromill sid Levelling your Micromill asasina a 18 Connecting your PC to the Micromill esccccccccccennnnncrinnnnnsnnsn 19 Connecting the Mains Supply 20 Removal of Protective Coatings s s wad Component Connection Schematic Diagram seessecsesneessesssneeseesesnnneeses 22 PC Specifications for your Micromill Controller 23 VR CNC Milling Software Installation oe cesesesestecseeseeseeseeseesneesnieeitsseeseicses 24 Section 4 Getting Started Using your Micromill Overview ceesceseseeseeseesesseesseesseesesssecsseessicseeesiesnesneeass General Layout of Micromill Components Micromill Front Panel Layout i Switching your Micromill On and Off ssscccccccccccennnnncrinnnnnnnns Starting the Machine Controlling Software s s sssssssssssisrsrsrssssrsrsrsnsnsrssnsnsnnnnnnss 29 General Layout of the Software essccccccrennnnriin
85. ntains the spindle speed and feedrate override potentiometer controls The spindle speed and feedrate of the Micromill can be manually Aito Made feediate overridden during a machining operation using the potentiometer and or spindle speed Controls fitted on the lower front panel of the machine illustrated changes will only be above e N On machines not fitted with these controls the software can be used spindle speed is being to override both spindle speed and feedrate see the next page applied by the controller The spindle speed can be overridden between 50 and 120 The feedrate can be overridden between 0 and 150 To increase the spindle speed or feedrate rotate the appropriate control clockwise To decrease the spindle speed or feedrate rotate the appropriate control anticlockwise Micromill CNC Milling Machine User s Manual Section 12 Part Manufacture 69 12 Overriding Feedrates and Spindle Speeds On CNC machines not fitted with potentiometer controls both the feedrate and spindle speed can be changed using the VR CNC Milling software slider bars shown below Software Feedrate Override Feed In Auto Mode feedrate and or spindle speed changes will only be registered when an actual feedrate or spindle speed is being applied by the controller Percentage readout The Feed panel displays a vertical slider bar and the current feedrate override displayed as a percentage Override values bet
86. ntervals specified in this manual to prevent the axes from seizing see the Maintenance section for further details Observe caution when adding or removing machine tooling When an emergency stop is required press the circular red emergency stop button located on the lower right front panel of the machine Micromill CNC Milling Machine User s Manual Section 2 Safety Features 13 2 Safety Features Emergency Stop Button Location of emergency stop button mounted on the righthand side of the machine lower front panel To active an emergency stop press the button fully in until it clicks A circular red emergency stop button is mounted on the righthand side of the Micromill CNC machine lower front panel When pressed ithas the effect of stopping all axes and spindle movements immediately The interlock switch will also close When the safety guard door is in its closed position this will prevent access to the working area of the machine To active an emergency stop press the button in until it clicks The emergency stop button will continue to cut all power to the machine drives and continue to keep the interlock switch closed until the release sequence is performed To release a closed emergency stop button push in and turn the button clockwise until it springs back out 14 Safety Features Section 2 Micromill CNC Milling Machine User s Manual 2 Safety Features Interlock Guard Switch Guard switch lock
87. o gt Swap Tool with gt Insert Tool In the example screenshot tool 2 is currently in the spindle We want to change to tool 1 so we right click on the number 1 graphic then highlight and click the Change To This Tool option Click the Tooling button on the Options toolbar to display the Machine Tooling window Right click on the number of the new tool you want to use then highlight and click the Change To This Tool option from the pop up menu that appears An Information window will be displayed prompting you to begin manually changing to the new tool number Always wait for the spindle and machine axes to stop moving before attempting to open the safety guard door After changing to the new tool number close the safety guard door then click the OK button on the Information window to update the tooling data used by the software Current Filename Default mtf Micromill CNC Milling Machine User s Manual 9 Manual Tool Changing with the Software During the running of a CNC program On reading a tool change operation line in your CNC program all three machine axes will move to their home positions via an intermediate point if programmed At this point the software will pause the CNC program and a a message window will be displayed similar to the one shown below tooling components may Prompting you to manually change tools be obtained by moving the machine head halfway down th
88. of Thrust Bearings 7 Cleaning the Datum MicroSwithes sssccccccccccccccnnnncnisnnnnnnnn 80 GID S Tip Adj stm nti ieena aaa 83 Spindle Drive Belt Adjustment oo sess ceseeseesseessecsecseeseeneesnessessesiesseesseess 87 Section 14 Technical Support Technical SUpport seme icessivvedereasisaivonseacadaasveh sed E E 88 Troubleshooting Changing COM Ports x BIG CIONICS Scrat aN i Ad eA E A E a 91 Section 15 Appendix Specification of Micromill CNC machine 94 Whatis a Part Program wots 96 Composition of a Part Program 97 GHC OMES AIS tas ratca dated AA coct ian A N A A A AGA 98 M Codes LIS Baccarat ecu E a O A E vena Hause arneatys 99 List of Program Address Characters 100 Denford Directives esses 101 EC Declaration OF Onfonmnity n Sestevsscesececlascedevessve cavseaivedeadguedtecedascebcessited ccassecia 103 Section 16 Glossary GOS SerYersbvcsvvvnssesiviandccsvvatetsietheventetedesssiadidegsuiiesginadidestuirieissndndescuitissginanlegcuittessitias 105 Section 17 Index MIM ENG E AAEE AAB APESS AEREE PTEE AEA EEE A ESEE EEE 109 Micromill CNC Milling Machine User s Manual Contents 5 Warning Notices A Warranty Disclaimer The Warranty on your Micromill CNC machine will be invalidated if any modifications additional ancillary equipment is fitted or any adjustments made to the controlling devices without prior notification from Denford Limited Please refer to the information held in yo
89. oftware wll Whatiis CNG naiiai aai 10 Section 17 Index 109 17 Index J Jog continuous ww Ad Step ou 44 Jog mode 43 Jogging the AXES oes eesseestesstesseesteeeee 45 L Layout of Micromill component 26 Leadscrews lubrication sesers Levelling your Micromill af Lifting your Micromill uo testes Linking to the Micromill siere 40 Loading a CNC file wo cece 31 Lubrication ANEAS ies A e 72 column leadscrew 15 column slideways a18 cross slide leadScrew eere 74 CTOSS Sideways oo eseeesseesseesstesstesstessteeseesneesees 71 table leadscrew 13 table slideways a16 thrust bearings a19 Lubrication chart sssssssssssssssssrsrsrsrsrsrsrsrsrsrererererere 71 110 Index Section 17 Machine tooling WindOW uo 36 Maintenance datum microswitches sssri 80 gib strips wee leadscrews lubrication areas lubrication chart SCNECUIC censissrehatnctenannatanenaseetialleentheten SIDEWAYS niania spindle drive belt thrust beanngs sonerii Maintenance schedule sssrinin 71 Manufacturing a part ch ckliS taranii oea 67 feedrate and spindle speed override 69 OVERVIEW fosron enas 25 running the CNC file we 67 stopping the machining process sss 68 Micromill front panel layout wesc eesseeseeseesneenees 27 introduction 9 jogging the axes machine communications parts identification 26 specification reiini 94 St
90. ol Diameter Flute Length Tool Length 34 Configuring Tools in the Software Section 6 Micromill CNC Milling Machine User s Manual 6 Adding New Tool Profiles Creating a Personal List of Tool Profiles The Tool Library allows a personal list of tool profiles to be created to match the real cutting tools used on your CNC machine Click the right mouse button on a highlighted tool title to display the Tooling Library window pop up menu Move the cursor down the list highlight and click on the Add Tool option A new tool will be created at the bottom of the current list of tools Type a name for the new tool and press the Enter key Changing Tool Data Values To display the data allocated to the new tool click the square next to its text title The new tool will inherit the data and graphic from the last tool highlighted in the library To edit a value in the tool data list double click the left mouse button on the data title required The Tool Data window will be displayed Click the cursor in any of the yellow tool data fields delete the old values and enter the new data Click the OK button to close the window and apply any changes made Changing the Tool Graphic To change the graphic allocated to the new tool displayed in the right panel of the Tooling Library window click the right mouse button on the new tool title to display the pop up menu Move the cursor down the list highlighting the
91. on points The hexagon washers should be positioned at this stage so they are open ie the off centre allen key holes on the bolts should be facing away from the grubscrews Now tighten the grubscrews in each miteebite to lock them firmly in position At this stage it should still be possible to remove the sub table Remember the grubscrews only lock the miteebites in position on the machine table itis the hexagon washers which actually lock the sub table in position To lock the temporary MDF bed firmly in place turn the bolts with the off centre allen key holes 180 degrees so the hexagon washers are in the closed position ie the off centre allen key holes on the bolts should now be facing towards the grubscrews Now that the miteebites have been set the sub table can be continually withdrawn from the machine table then replaced always to the same position This is an advantage for jobs involving the repeat milling of pieces of work such as a small production run ora college class group project Hexagon washer set Hexagon washer set in open position in closed position aa 58 Work Holding Section 10 Micromill CNC Milling Machine User s Manual 11 Introducing Offsets Jargon Buster 2 X The moveable workpiece datum defines the zero point on our workpiece the material we want to machine the starting point for any cutting co ordinates supplied by the machine controller The fixed machine
92. ont Panel Layout Spindle Speed and Mains P ower Emergency Feedrate Override Keyswitch and Button Stop Button Potentiometer Controls Spindle Speed and Feedrate Override Potentiometer Controls The spindle speed and feedrate of the Micromill can be manually overridden during a machining operation using the potentiometer controls fitted on the lower front panel of the machine illustrated above On machines not fitted with these controls the software can be used to override both spindle speed and feedrate Note the override feature will only operate when speeds or feeds are actually being applied to the work ie during a machining operation Mains Power Switch To activate power to the machine turn the keyswitch one quarter clockwise then push the circular red button When power is being supplied to the machine the circular red button will be illuminated Emergency Stop Button Pressing the emergency stop button has the effect of stopping all axes and spindle movements immediately To active an emergency stop press the button in until it clicks The emergency stop button will remain closed continuing to cut all power to the machine drives until the button is released To release push the button in and turn it clockwise until it springs back out Micromill CNC Milling Machine User s Manual Section 4 Getting Started 27 4 Switching your Micromill On and Off Follow these instructions to switch on your Micromi
93. ow easy access to both the top and bottom of the spindle head 2 Fit the spindle bar supplied into one of the holes on the threaded spindle body under the machine head Fita 1 2 or adjustable spanner around the drawbar hexagon bolt on the top of the machine head 3 Using the spindle bar to stop the spindle from rotating loosen and turn the drawbar hexagon bolt anticlockwise three turns see diagrams below Take care not to over loosen the drawbar hexagon bolt View Direction If the collet falls out but the tool remains inside Use adjustable or the collet you will need R 1 2 spanner to manually push the Drawbar tool out hexagon Machine Head Spindle MK SCGUI mee B X Bar A 4 Using a hammer gently tap the top of the drawbar hexagon bolt Never open the safety The tool will loosen or completely break free from the collet guard door and enter i the working area when 5 If you would also like to remove the collet continue to unscrew the spindle or machine the drawbar until the collet is released axes are moving Micromill CNC Milling Machine User s Manual Section 9 P reparing Tooling Hardware 47 9 Installing a Tool into the Drawbar Collet Installing a Tool E Drona 1 Move the machine head approximately halfway down the Z axis to allow easy access to both the top and bottom of the spindle y head e 2 If the collet is already in the spindle proceed to step
94. piece datum in the front left upper corner of the real billet on the machine table What happens if don t use any offsets with my CNC file If no offset is programmed the machine controlling software will use the machine datum as the starting point zero reference for any co ordinate movements it receives Since itis unlikely that the position of the machine datum is the place where you want any machining to begin your CNC machine will attempt to manufacture your design in the wrong place in its working area Offsets are very important because without them the CNC machine will not know where to begin cutting on your billet Offsets must always be configured before manufacturing the part Are standard offset files supplied eoa atik deines No you must set your own We DO NOT supply any standard offset the acon paint fh but files with the machine software However once you have configured CNC program the and saved your offset files the same files may be used over and starting position from over again so long as the following holds true which all co ordinates e The same cutting tools are used acta ine shape The billet size does not change plotted A e The fixture that holds the billet does not move position on the machine table Jargon Buster T X 60 Configuring Offsets Section 11 Micromill CNC Milling Machine User s Manual 11 Configuring a Workpiece Offset Movement Modes To switch between
95. ransfer the X Y or Z co ordinate values into the Workpiece Machine Offset file 1 Transfer the Co ordinate Value Check the Machine Mode window is configured to display workpiece co ordinates by clicking the Co ordinates button so that Work Piece Co ordinates is displayed in the statusbar Check that the required machine offset file is highlighted in the Work Piece Offsets window and its X Y and Z values are set to zero Click one of the three datum graphic buttons to the right of either the X Y or Z offset value display box the specific datum graphic button clicked will depend on which offset value is being configured 2 Specify the Cutter Orientation Before transferring the X Y or Z co ordinate value the Set Offset window is displayed The settings are used to account for the cutter orientation method used For example if the centre of the tool is aligned over the workpiece datum select the graphic with crosshairs over the centre of the tool and check the Use Cutter Radius option Click the green tickmarks or red crosses to change the options Click the OK button to confirm the settings 3 Check the Co ordinate Value has registered correctly The original X Y or Z co ordinate value from the Machine Mode window should have been transferred into the appropriate offset value display box The X Y or Z co ordinate value in the Machine Mode window should read zero indicating that the selected component of
96. rd The denstep motion control board is mounted in the top lefthand corner of the electrical panel It controls the motors that drive the three CNC machine axes Fuse LED Status and Fault Display The LED display is mounted on the lefthand side of the denstep motion control board Display Meaning Linear positional mode Torque control mode Stop asserted Pulse following mode Errors are all shown with a flashing dot Display Meaning External error Software abort or interpreter error Maximum servo following error exceeded Limit switch open o No comms board address fault 7 Servo power off 8 Servo power up and idle c Cam profiling G Cam table superscript C Circular interpolation 3 Encoder following mode F Flying shear static symbol H Homing datuming J J ogging velocity mode a Offset mode p q 5 U mnamo 92 Technical Support Section 14 Micromill CNC Milling Machine User s Manual 14 Electronics The Spindle Drive Board The spindle drive board mounted in the top righthand corner of the electrical panel controls the motor for the programmable spindle Two Spindle Drive Status LEDs Spindle Drive LED Status The two spindle drive status LEDs are mounted in the top lefthand corner of the spindle drive board Display Meaning ON LED Spindle drive board operational If this is not lit check the spindle drive board fuse shown in the diagram above then the f
97. right surfaces can be removed using a kerosene based solvent The coatings must be removed from the slideways before any attempt to move them is made Once these protective coatings have been removed all untreated surfaces should be coated with a light covering of machine oil e g BP CS 68 A Warning Only use kerosene based solvents in accordance with the solvent manufacturers instructions and safety recommendations Ensure that no naked flames are present The protective plastic sheeting on the guard windows should be removed and the glass and perspex cleaned with an anti static cleaner Micromill CNC Milling Machine User s Manual Section 3 CNC Machine and Software Installation 21 3 Component Connection Schematic Diagram YY Ancillary Equipment such as this printer connects to the Parallel porton the PC Personal Computer Desktop Tutor when ordered connects to the PC portlabelled COM 1 Parera CERN A zs The RS 232 cable connects the icromill to the PC port labelled COM2 The RS 232 cable is the long hin cable fitted with 25 pin emale connector at one end anda 25 pin male connector at he opposite end Connect the male end of the RS 232 cable to the 25 pin female RS 232 port on the side panel of he Micromill Connectthe female end of the RS 232 cable to the 25 pin or9 pin male COM2 porton the PC Mains Power Supply Plug Denford Micromill CNC The COM ports on
98. s which run in sequence are called blocks A block of data contains words sometimes called codes Each word refers to a specific cutting movement command or machine function The programming language recognised by the CNC the machine controller is an International Standards Organisation code which includes the G and M code groups Each program word is composed from a letter called the address along with a number These terms are illustrated on the following pages Micromill CNC Milling Machine User s Manual 15 Composition of a Part Program A componentis designed using a CAD E CAM software package such as Mill CAM Designer The CAD CAM software package automatically generates the part program including all the G and M codes required to manufacture the component Part Program example Mill CAM Designer triang MCD 3 3 1997 Novamill metric Post fanucm 1 2 24 J une 1994 G21 BILLET X8 Y55 Z10 EDGEMOVE X YO TOOLDEF T1 D2 N 1 G91G28XBY O29 N 2 M T1 N 3 G43H1 N 4O M3S1500 N 5 GI G X4 Y 48 N 6 Z2 N O70 G1Z 5F1 00 N 8 X72Y16F 159 N 9I X8 N 1 X4 Y 48 N 11 G Z2 12 X24Y 32 130 G1Z 1F 100 ae oe ara 140 X56F 150 158 X4 Y 16 16 X24Y 32 178 GOZ2 N 18 M5 N 19 G91G28X Y Z N 2 M30 en ee ee Micromill CNC Milling Machine User s
99. shown in its off MAIN POWER pos tion 28 Getting Started Section 4 Micromill CNC Milling Machine User s Manual 4 Starting the Machine Controlling S oftware Real Micromill CNC Machine S VA Miling Startbar Icon YR Milling Desktop Icon The movements and operational features of your Micromill CNC machine are driven by the VR CNC Milling software Notice thatthe VR CNC Milling software operates in two different modes i Virtual Reality Mode This is where a computer generated 3D model of your Micromill can be controlled within the confines of your PC see left This is commonly referred to as Offline ie away from the production line involving real CNC machines For more information on how to use the software in this mode please refer to the separate Virtual Reality CNC Milling Software Manual or the Windows helpfile contained in the software Machine Controller Mode This software mode is used when a real CNC machine such as your Micromill hardware is attached and controlled by the PC In this mode the Virtual Reality element of the software is not used The PC is used purely as a machine controller This mode is commonly referred to as Online ie directly involved with the operation of real CNC machines Follow these instructions to switch on the VR CNC Milling software 1 Switch on your Micromill CNC machine as described on the previous page 2 Power up the PC 3 Start the VR
100. slider bar mils j J og control U i50 value window F 102 0 S 150 0 T work Piece Co orc The J og tab is used for manually moving the CNC machine axes within their co ordinate working envelope J og Control Modes The J og panel displays the J og button a vertical slider bar and the jog control value window The machine table and head can be jogged or moved using two different methods outlined on the next page To change between these two methods click the J og button To change the jog control value click and hold down the left mouse button on the slider bar then drag the slider bar up or down to the new position When the Units of Measurement are set to Inch the rate of movement displayed in the jog control value window is measured using inches per minute When the Units of Measurement are set to Metric the rate of movement displayed in the jog control value window is measured using millimetres per minute Section 8 CNC Machine Control 43 8 J ogging the Axes og Mode J og Continuous In jog continuous mode the selected machine axis will move at the speed displayed in the jog control value window when one of the machine axis jog keys are pressed and held down The selected machine axis will continue to move until the key is released The slider bar can be moved to set jog speeds between 0 and 1000 units When J og Continuous is active the J og button graphic will be
101. table casting J ay Microswitch X Axis trigger bolt attached to machine table Micromill CNC Milling Machine User s Manual 13 Cleaning the Datum Microswitches Cross Slide Y Axis Datum Microswitch The microswitch defining the Y axis datum is positioned inside the rectangular thrust bearing casing on the front of the machine column base when viewed from the front of the machine Using a soft bristled brush carefully clean dust and debris away from the microswitch If the microswitch is being cleaned with the Y axis at its datum position as shown in the photo below take care not to disturb the trigger bolt attached to the end of the cross slide casting Location X Look at end of machine column base Lil Y Axis trigger bolt attached to machine saddle Microswitch Micromill CNC Milling Machine User s Manual Section 13 Maintenance 81 13 Cleaning the Datum Microswitches Column Z Axis Datum Microswitch The microswitch defining the Z axis datum is positioned inside the rectangular thrust bearing casing on the top of the machine column when viewed from the front of the machine Using a soft bristled brush carefully clean dust and debris away from the microswitch If the microswitch is being cleaned with the Z axis at its datum position as shown in the photo below take care not to disturb the trigger bolt attached to the machine head Location X Microswitch
102. the two modes of movement click the J og button in the Machine Mode window Use og Step Continuous for continuous movement when a movement key is pressed and held down The slider bar can be moved to set jog speeds between 0 and 1000 units Use this mode for rough positioning Use og Step Mode for a single increment movement each time a movement key is pressed The slider bar can be moved to set jog increments of 0 01 0 1 0 5 1 5 and 10 units Use this mode for precise positioning Micromill CNC Milling Machine User s Manual The workpiece offset file contains three values used to describe the location of your workpiece datum They determine how much you want to shift the zero reference position of the CNC machine along the X Y and Z axes However if your CNC file uses two or more tool profiles the workpiece offset file will not account for the difference in length between the tools To achieve this you must also configure a tool offset value for each tool profile you intend to use see page 64 Before you can begin entering the workpiece offset values you must position the tool over your workpiece datum Move the Tool over the Workpiece Datum Highlight the Machine Mode window and select the J og tab To move the tool use the six movement keys X Axis Cursor Right or Cursor Left Y Axis Cursor Up or Cursor Down Z Axis Page Up or Page Down Remember the tool and mach
103. tighten locking screw when viewing the face of the locking screw 2 Push the wider end of the gib strip further up into its channel to eliminate the free play in the slideway The gib strip is best accessed by reaching around the back of the machine head shown below Remember that a slight degree of movement must be left in the slide to allow the slide to move Location X Look at back of machine head Gib strip an guide pin 3 Tighten the gib strip locking screw 4 Move the machine table left and right across the saddle to ensure that the movement is smooth 5 If the movement is not smooth adjust the gib strip by repeating Steps 1 to 3 Run the machine table again to assess the smoothness of movement 86 Maintenance Section 13 Micromill CNC Milling Machine User s Manual 13 Spindle Drive Belt Adjustment Location ax Look under spindle motor bracket View of two motor adjusting bolts under motor bracket Spindle pulley Drive belt Machine head The drive belt from the motor to the machine spindle may become Slack from time to time due to constant use To adjust the tension release the two bolts holding the motor Slide the motor further away from the spindle until slack in the drive belt has been eliminated then tighten the two bolts holding the motor 3 Slide motor further away from spindle to tighten drive belt 1 Release motor bolt 1 2 Rele
104. two types of file the workpiece offset and the tool offset Used to describe the workpiece datum a zero reference used on the CNC machine to ensure machining occurs in the correct place on the billet Offsets are used to shift parts of the three dimensional co ordinate based grid system used by the CNC machine PART DATUM uu seeeeteseee Used as a zero reference point in a CNC file All machining co ordinates originate from this point Pe aaan aiani Personal computer PRY iiinn Denford CNC Project file extension prj Project files contain global information about user defined settings in the VR CNC Milling software such as toolpost set up tooling library offsets toolbar and window positions etc PROGRAM iirinn A systematic arrangements of instructions or information to suita piece of equipment RAPID TRAVERSE sss Fast movement of the cutting tool through the 3 machine axes between cutting settings REFERENCE POINTS The machine has 3 reference points used in setting the limits of movement for its Slides axes RPM aieea Revolutions per minute rev min a measure of spindle speed SIMULATION OFFSET The workpiece offset file only used with VR CNC Milling software 2D and 3D graphics SLIDES aaisa The 3 machine axes see axis SPINDLE SPEED rinii The rate of rotation velocity of the machine head cutting tool measured in RPM SUB TABLE isiin A secondary table that is clamped to the actual machine table The work
105. un the ta Slideways ble fully along the X axis to distribute the oil along the Distribute oil along the front A and back B slideways arrowed Micromill CNC Milling Machine User s Manual 13 Lubrication of Slideways Cross Y Axis Slideways Lubrication Run the saddle fully forward to expose the back section of the column base slideways Using a pump oilcan with a flexible nozzle or an aerosol directly lubricate the exposed surfaces of the two table slideways Run the saddle fully back against the machine column to expose the front of the column base slideways Directly lubricate the remaining exposed surfaces of the two table slideways Run the saddle fully along the Y axis to distribute the oil along the Slideways Locati X Distribute oil along the SN baka Aa left A and right B Look at sides of column slideways arrowed base Micromill CNC Milling Machine User s Manual Section 13 Maintenance 77 13 Lubrication of Slideways Column Z Axis Slideways Lubrication Run the machine head fully up to expose the bottom of the table S a Location X Look at sides of column 78 Maintenance Section 13 aD nNwMN ideways un the mach ideways Using a pump oilcan with a flexible nozzle or an erosol directly lubricate the exposed surfaces of the two table ne head fully down to expose the top of the table ideways Directly lubricate the remaining exposed s
106. ur separate Warranty pack for specific details Do not carry out any portable appliance testing PAT on any of the supplied equipment Maintenance Disclaimer Always obtain permission from the person responsible for machinery in your establishment before accessing the electrical panel at the rear of your Micromill CNC machine casing to carry out any maintenance work All work must be carried out by personnel suitably qualified for each maintenance task to avoid damage to both the machine systems and the maintenance personnel Denford Limited cannot accept responsibility for any damage and or loss that may occur through incorrect maintenance of your Micromill CNC machine A F oreseen Use of Machine Your Micromill CNC machine is designed for milling synthetic materials such as wax plastics acrylics and non hardened metals such as aluminium In each case the appropriate tooling spindle speeds and feedrates should be used as recommended by the material supplier Only use water based soluble oil cutting fluids do not use parafinic or potentially explosive cutting fluid Do not attempt to use your Micromill CNC machine for manual operations Never attempt to fit an abrasive wheel to the machine spindle If you have any doubts and or questions regarding the specification servicing or features of your machine please contact Denford Customer Services Denford Limited reserves the right to change the specification and or operating featur
107. urement are set to Metric the co ordinates are displayed using millimetres Work Piece Co ordinates Display System The Work Piece Co ordinates system displays the co ordinate position values relative to the moveable workpiece datum defined through use of the machine offset facility Machine Mode Home Jog Auto XxX 154 700 Y 54 400 66 300 Co ordinates display panel Co ordinates button setto Workpiece co ordinates Statusbar Machine Co ordinates Display System The Machine Co ordinates system displays the co ordinate position values relative to the fixed machine datum Machine Mode F 102 0 s 150 0 E work Piece Co or Home Jog Auto Co ordinates display panel Co ordinates button set to Machine co ordinates M Codes pi Z Offset Coolant F 600 0 s 150 0 Machine Co ordin Statusbar 42 CNC Machine Control Section 8 Micromill CNC Milling Machine User s Manual 8 J ogging the Axes og Mode In order to move any of the machine axes the Jog panel of the Machine Mode window must be active ie the titlebar is highlighted and the words og are highlighted in green Micromill CNC Milling Machine User s Manual Machine Mode XxX 154 700 Home Jog Auto J og panel o 99 Spindle Y 54 400 Ie J og button m y OA me M Codes Co Ordinates aL HE ae Z Offset Coolant J og
108. urent Filename Default mtf Micromill CNC Milling Machine User s Manual Section 6 Configuring Tools in the Software 37 7 Running a 2D Simulation of a CNC File Before running the 2D simulation Check that the units of measurement set for the VR CNC Milling software matches the units used in both the CNC file and any tooling profiles The units of measurement setting for the VR CNC Milling software is configured using the Units button on the Options toolbar Check that the tool numbers and tool profiles used in the Machine Tooling window match those used by your CNC file 38 Simulating a CNC File Section 7 The 2D Simulation window provides a plan view of the billet together with a graphical representation of any machined parts 2D Simulation To display the 2D Simulation window click the 2D Simulation button shown above from the Outputs toolbar To close the window click the 2D Simulation button again Click the Use X Y Offsets option on the 2D Simulation menu so a tick mark is not shown next to the title This will display the 2D simulation without using any simulated offsets To run the CNC file ensure the Editor window cursor is positioned at the start of the first line of the CNC file File Control Click the triangular P lay button from the File Control toolbar shown left gt DOLI The graphics in the 2D Simulation window shown below are updated accordin
109. urfaces of the two table slide Run the mach ways ine head fully along the Z axis to distribute the oil ong the slideways Distribute oil along the left A and right B ap _ slideways arrowed Micromill CNC Milling Machine User s Manual 13 Lubrication of Thrust Bearings COO Table X Axis Thrust Bearing Lubrication Look at right end of Using a pump action table J l i oilcan pump oil directly ot por poin onto the two exposed shafts of the thrust a i bearing shown left sgl za Using a pump action oilcan pump oil directly onto the two exposed shafts of the thrust bearing shown left Using a pump action oilcan pump oil directly onto the two exposed Shafts of the thrust bearing shown left Micromill CNC Milling Machine User s Manual Section 13 Maintenance 79 13 Cleaning the Datum Microswitches Location X Look at right end of machine table 80 Maintenance Section 13 Table X Axis Datum Microswitch The microswitch defining the X axis datum is positioned inside the rectangular thrust bearing casing on right end of the machine table when viewed from the front of the machine Using a soft bristled brush carefully clean dust and debris away from the microswitch If the microswitch is being cleaned with the X axis at its datum position as shown in the photo below take care not to disturb the trigger bolt attached to the end of the machine
110. use labelled F1 on the main fuse rack see the diagram on page 111 STALLLED Motor stall This indicates a faulty motor or component on the spindle drive board Micromill CNC Milling Machine User s Manual Section 14 Technical Support 93 15 Specification of Micromill CNC machine Standard Equipment Micromill CNC machine VR CNC Milling operating software Tailored courseware and project books CNC machine and controller software manuals Set of maintenance tools and spare parts list Machine commissioning and basic instruction Training UK Only Extra Equipment Various tooling packages Additional CAD CAM software Additional offline VR CNC Milling software licenses Machine work bench Video conferencing system Training PC amp PC workstation Workholding vice Miteebite clamps Safety Features Manual operation totally enclosed interlocked safety guard door Emergency stop button 2D and 3D simulation graphics to verify part programs prior to machining Automatic tool retraction amp spindle stop for tool changing Key operated power switch Program protect keyswitch preventing student tampering 94 Appendix Section 15 Micromill CNC Milling Machine User s Manual 15 Specification of Micromill CNC machine Mechanical Details Table size 70mm x 330mm 2 3 4 x 13 2 tee slots 6mm width 38mm centres Travel X axis Standard and Micromill 2000 229mm 9 Travel Y axis Stand
111. ween 1 100 are set in the lower grey portion of the slider bar Override values between 100 150 are set in the upper red portion of the slider bar To change the feedrate value click and hold down the left mouse button on the slider bar then drag the slider bar up or down to the new position When the Units of Measurement are set to Inch the feedrate is measured using inches per minute When the Units of Measurement are set to Metric the feedrate is measured using millimetres per minute S oftware Spindle Speed Override Spindle Percentage readout 70 Part Manufacture Section 12 The Spindle panel displays a vertical slider bar and the Current spindle speed override displayed as a percentage Override values between 1 100 are set in the lower grey portion of the slider bar Override values between 100 120 are set in the upper red portion of the Slider bar To change the spindle speed value click and hold down the left mouse button on the slider bar then drag the Slider bar up or down to the new position The spindle speed is measured using revolutions per minute Micromill CNC Milling Machine User s Manual 13 Maintenance Schedule and Charts Maintenance Schedule Daily Clean and remove any swarf e Check that all slides are lubricated e Clean tooling and tool holders Weekly Clean the machine e Check all exposed screws and nuts for tightness Qil all slides leadscrews and thrust
112. your PC may be labelled as Serial Milling Machine ports All COM ports have a 25 pin or 9 pin MALE connector The Parallel port on your PC may be labelled as the Printer port The printer porthas a 25 pin FEMALE connector 22 CNC Machine and Software Installation Section 3 Micromill CNC Milling Machine User s Manual 3 PC Specifications for your Micromill Controller Your Micromill CNC machine is controlled using a standard IBM compatible PC personal computer To run the VR CNC Milling software and connect to the Micromill electrical control box your PC hardware must meet the minimum specification listed below Minimum Specification IBM PC or 100 compatible personal computer e Pentium 120MHz processor 24Mb RAM Windows 95 Operating System Double speed CD ROM drive Microsoft 100 compatible mouse 10Mb Free hard disk space e Colour Monitor running at 800 x 600 resolution with 16bit High Colour graphics e SVGA graphics card with 512KB VRAM 1free serial COM port e 1 free parallel printer port Recommended Specification IBM PC or 100 compatible computer Pentium 166MHz MMX processor 32MbRAM Windows 98 Operating System Double speed CD ROM drive Microsoft 100 compatible mouse 10Mb Free hard disk space e Colour Monitor running at 1024 x 768 resolution with 16bit High Colour graphics 3D accelerator card with 4MB VRAM Windows compatible soundcard

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