Milling machine
We assume the loaded NCP-file for the machine is correct. I.e., the top of the workpiece is (x,y,z) 0,0,0 and the workpiece is in the positive x-y area (See Milling).
Contents
Operating panel
- Indicators computer
- Emergency button
- Fault indicator
- Power button
- Start button
- Stop button
- Button for opening cover
- Acknowledge button
- Key
Powering on
Make sure the cover doors are closed. Turn the main switch on the side of the machine with a quarter of a turn. A blue light will lit up.
Press shortly on a black switch next to the screen of the computer to power on the computer. Indicators [1] light up.
Press the power button [4] if it is not lit up. Log on locally with the following credentials found on \\srv850.tudelft.net\toi\Projects\Modellen_Onderzoek\000.Documentatie\frees_LP.txt
Controller software
Start Remote. This is the programme for operating the milling machine.
After start up the programme will ask for a Reference run. Click OK and the spindle head will move to the left back of the machine to its home position.
The most important buttons for operating the machine are highlighted in the figure below.
Shows a graphic representation of the NCP-file
Resets the controller software after a fault. Fault indicator [3] lights up. Before resetting press the power button [4] when unlit.
Moves the head automatically to one of the pre set machine postions.
- Parkpostion: a postion in the middle of the machine
- WPZero: zero point on the workpiece i.e. front-left corner on the top of the piece to be milled.
- HomePosition: the left back position in the machine
Opens a dialog box to edit one of the pre set machine positions. In general only WPZero will be edited.
Opens a dialog box to move the spindle head manually.
Changes the current tool, or gets a tool when there is no tool in the spindle.
Puts the current tool away in the toolholder when there is a tool in the spindle.
Measures the length of the current tool. After every tool change the length of the tool is always measured.
Opens or closes the cover of the toolholder.
Aborts the current milling operation
Pauses the current milling operarion. Click on start to resume.
Starts a milling operation or resumes the current operation.
Milling
Opening the cover
The cover button [7] lights up when the cover is ready to be opened. To open the cover keep the cover button [7] pressed to release the lock. While pressed move the handle of the cover downwards. If for some reasons the cover button does not light up, turn the key [9]. The cover button [7] and the acknowledge button [8] light up. Keep both buttons [7][8] pressed while opening the cover.
Securing the workpiece
Move the clamps towards the side of the workpiece. Fasten the clamps with an Allen key on the milling table. Before fastening the clamps make sure the levers are away from you. Turn the levers towards you to secure the workpiece.
Loading the NCP-file
- Open the file and something like below will appear with a lot of code.
- Check which tool is needed in each position. Search with CTRL-F for similar lines with GETTOOL
- The next line must have a RPM value higher than zero.
- Open the graphic representation of the file to check the position of the WPZero on the workpiece. It should be on the top left-hand corner of the workpiece.
Changing tools
- Change the tools according to the NCP-file. See the picture for the corresponding positions with the tool numbers.
- Open the cover of the toolholder.
- Remove the tool from the holder. Change with the approriate tools the milling bit and put the tool back in the toolholder.
Moving the toolhead
The cover needs to be closed at all times, when you want to move the toolhead.
- Close the cover.
- Turn the key when the acknowledge button [8] still lights on.
- Press the power button [4] if unlit.
- Reset the machine to be sure. You will hear a click from the machine.
- Move the toolhead anywhere you want.
Setting the zero point
In general you have only set the zero of the Z-axis. This is the top of your workpiece. The settings for X and Y axes are in most cases fine. These are the left side and the front of the workpiece as well as the milling table.
- Open the Machine positions dialog box.
- Select the highlighted row (WPZero) and click on Single axis.
- Select CAN-Z to set the zero point of the Z-axis.
- Move the tool somewhere on the top of your workpiece with the X and Y axis buttons and lower the toolhead towards the workpiece with the Z-axis button. Click first on Endless to move the toolhead continuously. When the toolhead is very close on the top of the workpiece you can move the toolhead gradually. You may choose 1.00 to move the toolhead per millimetre towards the top of the workpiece or lower values to lower the steps.
- Confirm with OK on all open dialog boxes.
Milling operation
- Move the toolhead manually somewhere away from the workpiece.
- Start the milling operation. The spindle starts turning and moves towards the workpiece.
For some reasons you may want to pause the milling operation and continue later on.
- Pause the milling operation. The head stops moving.
- Stop the spindle spinning.
- Start the spindle before resuming.
- Continue with the milling operation.