Programming, Cutting, and Cleanup

To load your program, begin by transfering the program from the computer to the mill.

• The mill requires a file name of 4 or 5 numbers - no letters.
• The file extension is .nc
• Ensure your program numbers match your Setup Sheets.
  1. Setup 1 = 1001.nc, Setup 2 = 1002.nc, etc.

1. Post process G-code to the thumb drive.
2. Insert the thumb drive into the USB port on the controller.
3. Press LIST PROG to open the Program Manager.
4. Press CANCEL to go up a level.
5. Select USB DEVICE and press WRITE/ENTER.
6. Navigate to your .nc program.
   • Double check the date on the file.
7. Press F2.
8. Select Memory and press WRITE/ENTER to write your program to memory.
   • If there's a name conflict, press Y to overwrite the old file.
9. Press EDIT (mode key) and SETNG GRAPH (display section).
10. Press CYCLE START.
    • This will run a graphic simulation of your program.
    • The machine will not move.
    • When the simulation is over, the status bar will briefly display M30 Found.
    • If you have an error, see Shop Staff.

You're ready to run the program. Double check that these tasks have been completed.

• Check the setup sheet to ensure all tools have been loaded.
• Actual material size has been measured, entered into CAM and toolpaths regenerated.
• Tool length offsets were set for custom tools.
• Work offset (G54) has been set.
• The clamp distance is at least 1/8", and part stickout is enough to avoid hitting the vise.
• The program has been simulated to check for errors.

Using coolant

Because of the spindle's high speed and feed rate, flood coolant is required.

• Behind the spindle, there are two ball valves.
  • Open the valve on the left.
  • The handle should be perpendicular to the doors.

Note: The system may be pressurized; prepare for a bit of spray.

1. Press MEM to access machine memory.
2. Press SINGLE BLOCK.
3. Press 5% RAPID.
4. Hold one finger over the red FEED HOLD button.
5. Press CYCLE START once.
6. Press CURNT COMDS.
7. Use PAGE UP to navigate to the Position screen.
   • The Position screen shows the current position of the tool tip and Distance To Go.
8. Press CYCLE START until the tool starts to move in Z towards your part.
   • Compare Work Offset G54 Z position with the actual distance in the mill.
   • If it looks like there will be a collision, press FEED HOLD.
   • If coolant is blocking your view, press COOLNT to turn it off.
   • If the tool tip stops 0.6" above your material, the Tool Offset is correct.
9. 9. Turn the coolant back on.
10. Press SINGLE BLOCK to exit Single Block mode.
11. Press CYCLE START to start machining.
12. After the next tool change, press SINGLE BLOCK again.
    • Use SINGLE BLOCK until the tool is 0.6" above the stock.
    • Repeat for each new tool.

Single Block mode

Single Block allows only one line of the .nc file to be executed for each push of CYCLE START.

• Use Single Block to step through the program and double check tool offsets.
  
  • Your .nc file should move the cutting tool to 0.6" above the stock and pause.
  • This will give you a chance to stop movement if something goes wrong.
• Single Block must be turned off before actually cutting material.

FEED HOLD button

FEED HOLD stops the table and head movement. It does not stop the spindle.

• Use FEED HOLD to pause the machine for inspecting parts or cutters.

Once the machine is paused, you may want to stop coolant spray or stop the spindle.

SPINDLE STOP button

Press STOP (in Overrides) to stop the spindle so you can open the door.

• The mill will not automatically restart the spindle when restarting the program.
• If you stopped the spindle you must press CW (clockwise) to restart the spindle before pressing CYCLE START

COOLNT

Press COOLNT (in MDI DNC) to toggle coolant on or off.

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Don't remove the part yet.

When your program is finished, inspect the part before removing it from the vise. If there is a problem, you can do more machining.

• Modify or add a toolpath.
• Post process just that toolpath.
• Load the new program into the machine.
• There is no need to reset the WCS.

Plan on 30 minutes to clean the mill.

Remove the tools

1. Navigate to the Pocket Tool Table.
2. Remove the tool in the spindle with the tool release button.
3. Put the tool away.
   • Remove custom tools from holders.
4. Put a 0 in the Pocket Tool table.
5. Remove any notes for heavy or large tools.

Repeat for all tools except the probe.

Chip auger

Pressing CHP FWD in the Jog panel will run an auger to move chips into the recycle bin.

• The auger is just inside the mill, under the door.
• Make sure you do not get caught in the auger when reaching inside the machine.

Using compressed air

Compressed air forces chips into the moving parts of the mill and can cause it to lose accuracy.

• Use compressed air to dry parts and parallels, outside the mill.
• Do not use it to clean the mill.

Double check your work

• Check the Pocket Tool table for all 0s, except the probe.
• Check the carousel for tools.

Hose out the mill

1. Close the coolant valve by the spindle.
2. Turn on coolant at the control panel.
   • This will pressurize the hose.
3. Turn on the auger.
4. Wash the chips off the bed, vise, walls and windows.
   • Jog the bed and spray under it.

Final Steps

1. Turn off the coolant.
   • Release pressure on the hose.
2. Turn off the auger.
3. Close the doors.
4. Turn off the mill - E-stop then POWER OFF.
5. Clean the area, including tables and the floor.
6. Make sure all the tools are put away and custom tools are removed from the holders.