1. The Milling Machine

2. Care and Maintenance of Milling Cutters
The life of a milling cutter can be greatly prolonged by intelligent use and proper storage.
Take care to operate the machine at the proper speed for the cutter being used, as excessive speed will cause the cutter to wear rapidly from overheating.
Take care to prevent the cutter from striking the hard jaws of the vise, chuck, clamping bolts, or nuts.
Whenever practical, use the proper cutting oil on the cutter and workpiece during operations, since lubrication helps prevent overheating and cutter wear.
Keep cutters sharp. Dull cutters require more power to drive and this power, being transformed into heat, softens the cutting edges. Thoroughly clean and lightly coat milling cutters with oil before storing.
Place cutters in drawers or holders so that their cutting edges will not strike each other.
Never operate a cutter backwards.

3. Checklist Before you enter work area Put on safety glasses
Tie back loose hair and clothing
Remove jewelry including rings, bracelets, and wristwatches
Do not use any piece of equipment until instructor has demonstrated proper operational procedures and individual safety rules
Do not use any equipment or tools that are broken and report any broken equipment or tools immediately

4. Checklist Before machining a part
While setting up work, install the cutter
last to avoid being cut.
When installing or removing milling cutters, always hold them with a rag to prevent cutting your hands.
Make sure you have the correct tool for the job.
Secure the tool properly.
Make sure all tool positions have been properly initialized.
Verify the NC program on the computer before machining.
Remove all loose parts and pieces from the machine.
Remove adjusting keys and wrenches from the machine.
Close the safety shield.

5. Checklist Before machining a part Perform a dry run.
Set the spindle motor switch to lowest manual speed setting.
Make certain there is no work piece in place.
Run the NC program to make sure all the moves make sense before running the program with a work piece in place.
After completing the dry run, properly secure the work piece to the machine.
Keep fluids away from all electrical connections, electronic or electrical devices, the computer, and nearby electrical outlets.

6. Checklist While machining a part
Do not touch moving or rotating parts.
Do not place or remove anything from the work area while machine is running.
Press the Emergency Stop button before re-opening the safety shield.
Only open the safety shield after the spindle has stopped rotating.
Press the Emergency Stop button whenever changing tools or mounting or removing a work piece.
Pull the Emergency Stop button out only after closing the safety shield.
Keep all unauthorized persons away from the work area.
Always leave work area clean and orderly.

7. CNC Speed and Feed Capabilities
Machines
CIM
Machining
CNC Speed and Feed Capabilities
Super Prolight 1000
Linear Feed Rate
0.1 – 75 ipm
(2 – 1905 mm/min)
Circular Feed Rate
X,Y Rapid Feed
75 ipm
(1905 mm/min)
Z Rapid Feed
Speed Range
0 - 5,000 RPM
Prolight 1000
Linear Feed Rate
0.1 – 25 ipm
(2 – 635 mm/min)
Circular Feed Rate
0.1 – 18 ipm
(2 – 457 mm/min)
X,Y Rapid Feed
50 ipm
(1270 mm/min)
Z Rapid Feed
40 ipm
(1016 mm/min)
Speed Range
0 - 5,000 RPM
M103 * moves spindle to up limit
M102 * moves table to front limit
M101 * moves table to left limit
M112 Home Z
M111 Home X
Project Lead The Way, Inc.
Copyright 2008

8. CNC Prolight Z Axis Stepper Drive Motor Safety Shield Cross Slide1
Z Axis Stepper Drive Motor
Safety Shield
Cross Slide
Spindle Motor
Spindle Head
X Axis Stepper Drive Motor
Y Axis Stepper Drive Motor 1 4 2 5 3 6 4 2 5 3 6 7 7

9. Manual Control Panel Manual Spindle Speed Emergency Stop
Machines
CIM
Machining
Manual Control Panel
Manual Spindle Speed
Emergency Stop
Manual to CNC Switch
Project Lead The Way, Inc.
Copyright 2008

10. Adjusting a Machinist Vise
Machines
CIM
Machining
Adjusting a Machinist Vise
As you tighten the yellow draw bolt into the blue cross bar the front vise jaw will close. The draw bolt has a limited distance of travel. If the draw bolt has reached its limit and has not tightened against the stock material, the blue cross bar must be adjusted to the next location on the rack.
Note: The blue cross bar has enough play to move side to side and get stuck in the outside holes in the body. If this happens, the draw bolt will not be able to adjust to another location on the rack. The cross bar must be re-centered in the underneath gap in order to move around.
Project Lead The Way, Inc.
Copyright 2008

11. Other Vises / Hold Downs
Low Profile Clamping Kit
Step Blocks and Strap Clamps
2 Axis Pneumatic Vise
One Axis Pneumatic Vise

12. Loading / Changing a Quick Change Collet
Move the Z axis to a safe location
Press the emergency button
Open the safety
shield
Insert the chuck
lock pin

13. Loading / Changing a Quick Change Collet
Machines
CIM
Machining
Loading / Changing a Quick Change Collet
-Rotate the collet until the silver dot on the collet lines up with the locking pin hole
-Two pins inside the collet will line up with the groove on the tool holder
-With the collet locking pin still in place, tighten the collet ring
-REMOVE the locking pin
Project Lead The Way, Inc.
Copyright 2008

14. Edge Finder in Tool Holder
Milling Bits
Specialty Tools
Common Tools
Double End Bit
Roughing End Mill
Long End Mill
Engraver
Edge Finder in Tool Holder

15. Machine Zero / Home +Z +X +Y -X -Y -Z

16. Part Zero +Z +X +Y -X -Y -Z

17. CNC Machine Axes PRZ Part Reference Zero +Z Origin 0,0,0 -Z +X +Y -Y

18. Top View Part Reference Zero (PRZ) Position Yp D= tool diameter
Machines
CIM
Machining
Part Reference Zero (PRZ) Position Yp
D= tool diameter
- x offset = D/2
Cutting Tool
- y offset = D/2
Top View
(0,0,0) PRZ Position
Work Piece Ym Xp
Part Axes Xm
Machine Axes
Project Lead The Way, Inc.
Copyright 2008

19. Part Reference Zero (PRZ) Position
Machines
CIM
Machining
Part Reference Zero (PRZ) Position Zp
Front View Xp
Work Piece
(0,0,0) PRZ Position
Note: x offset = y offset = D/2
z offset= 0
Project Lead The Way, Inc.
Copyright 2008

20. Machines
CIM
Machining
Checking PRZ
Send the Mill to a point above the x and Y zero to make sure the center of the cutting tool is over the top front corner.
Project Lead The Way, Inc.
Copyright 2008

21. Using an Edge Finder True Spin Not Touching Material
Machines
CIM
Machining
Using an Edge Finder
True Spin
Not Touching Material
Offset Spin (Jump)
Touching Material
Load the edge finder in the mill
Load the material in the vise
Close the shield
Manually turn on the spindle in the software at suggested speed for the edge finder (typically no faster than 1000 rpm)
Lower the edge finder down past the negative edge of the material
Move in .1 increments (Step B) toward the material until the edge finder jumps over.
Back off .2 (Step B x 2) (or until the edge finder again spins true)
Move in .001 increments (Step A) toward the material until the edge finder jumps over.
Back off .002 (Step a x 2) (or until the edge finder again spins true)
Note: Most edge finders have a diameter of .2 leaving the bit at -0.1 offset
Edge finders are used to find X & Y Edge, not Z (Top) Surface
Project Lead The Way, Inc.
Copyright 2008

22. Tool Library Machines CIM Machining Project Lead The Way, Inc.
Setting up the tool library properly is a critical step. Once the tool library is setup it does not need to be changed unless a new tool is loaded into a an existing tool holder. During setup the tool is defined by its geometry, size, number of teeth and relative length (Height Offset).
Some of the information in the tool library is simply used when verifying programs. For instance, the NC program only directs the center of the tool so the verify program needs to know the diameter of each tool to show how much material is removed. The tool offsets and tool numbers, however, are very important when running programs with multiple tools. Each tool must be defined with a Tool Height Offset.
Project Lead The Way, Inc.
Copyright 2008

23. Machines
CIM
Machining
Tool Setup
The first step in setting up a tool library is to home the machine. The homing process will send the mill to a known position along all three axes. Follow the steps below to home the machine.
Select Setup in the menu bar and then Set/Check Home
Hold the Control key and type H
Right click on the Jog Control Panel and select Set/Check Home
Select the Home icon from the tool bar
Home
Project Lead The Way, Inc.
Copyright 2008

24. Machines
CIM
Machining
Tool Height Offsets
When a tool offset is established, the control program calculates its height move using the offset.
Where does the mill spindle go when it is directed to a height of .5?
Tool Height Offset
Project Lead The Way, Inc.
Copyright 2008

25. Machines
CIM
Machining
Tool Setup Wizard
A wizard is available for setting up tools. Select Tool - Setup Tool Wizard from the main menu.
Click Next
The first tool established a reference height.
Project Lead The Way, Inc.
Copyright 2008

26. Machines
CIM
Machining
Tool Setup Wizard
To put the reference tool in the spindle, click here.
Click on Next.
Project Lead The Way, Inc.
Copyright 2008

27. Machines
CIM
Machining
Tool Setup Wizard
Offset gage - Works as a continuity check. The light shines when a complete circuit is made by touching the tool and table.
Click Next to continue.
After inserting the reference tool, use the jog control panel to put the end of the cutting tool on the top of the block.
Project Lead The Way, Inc.
Copyright 2008

28. Tool Setup Wizard Remove the Reference tool and then select Next.
Machines
CIM
Machining
Tool Setup Wizard
Remove the Reference tool and then select Next.
You’re Done! Note that the Z coordinate in the Position Panel changes to zero. The current height is now the reference point. All other tools heights will now be compared to this.
Project Lead The Way, Inc.
Copyright 2008

29. Machines
CIM
Machining
Tool Setup Wizard
If the tool library has other tools defined, you may now select them to set the tool height offset.
If the tool is not in the library, you will need to set it up.
Project Lead The Way, Inc.
Copyright 2008

30. Setting Up the Tool Library
Machines
CIM
Machining
Setting Up the Tool Library
Type in a tool description.
Enter the diameter.
Select the tool number. This will be identified as tool 1 (M06T1).
Project Lead The Way, Inc.
Copyright 2008

31. Setting Up the Tool Library
Machines
CIM
Machining
Setting Up the Tool Library
Select the type of tool.
An End Mill has a flat bottom. Center cutting is recommended since plunging is often required.
A Bull Mill has a nose radius on its corners - Define the radius here.
Project Lead The Way, Inc.
Copyright 2008

32. Setting Up the Tool Library
Machines
CIM
Machining
Setting Up the Tool Library
Select the type of Tool
An engraving tool is a type of tapered cutter.
Define the taper angle
A Ball Mill has a constant radius (1/2 diameter) on its end.
Define the diameter at its end point
A Standard Drill (118° Point).
Project Lead The Way, Inc.
Copyright 2008

33. Setting Up the Tool Library
Machines
CIM
Machining
Setting Up the Tool Library
Load the tool in the spindle and set the parameters.
Project Lead The Way, Inc.
Copyright 2008

34. Setting Up the Tool Library
Machines
CIM
Machining
Setting Up the Tool Library
Jog the machine so the tool is touching the top of the reference point (Tool offset Gage)
Project Lead The Way, Inc.
Copyright 2008

35. Setting Up the Tool Library
Machines
CIM
Machining
Setting Up the Tool Library
Set the tool Height offset by clicking Current Z.
Project Lead The Way, Inc.
Copyright 2008

36. Setting Up the Tool Library
Machines
CIM
Machining
Setting Up the Tool Library
Note that the position panel shows a z height of zero. The control software has calculated the difference between the reference tool and tool 1.
Project Lead The Way, Inc.
Copyright 2008

37. Setting Up the Tool Library
Machines
CIM
Machining
Setting Up the Tool Library
Tool Height offset
Continue setting up as many tools as necessary in the library. Any time that a tool is removed from the tool holder (not the spindle) the height offset must be reset. Now lets take a closer look at some more options in the tool library.
Project Lead The Way, Inc.
Copyright 2008

38. Machines
CIM
Machining
Setup Tool Library
Station locations are used for mills equipped with automatic tool changers.
Identify tool material (high speed steel is a good general purpose tool).
Number of teeth (flutes) in the cutting tool.
Always apply any changes before continuing to the next tool.
Project Lead The Way, Inc.
Copyright 2008