CNC Router

The CNC Router is located by the large overhead door next to GT Solar Racing and Wreck Racing. The machine has a capacity of 4'x8' in X and Y and roughtly 5" of travel in Z. All users that use this machine should have previous knowledge of a CAM software (such as Fusion 360 or HSM Works) and be familiar with generating toolpaths. The control is located on the desktop computer to the left of the machine

Safety Rules:

  • When spindle is on, never put your hands over the edge of the table.

  • Ensure that everyone in the area is aware of the machine basics, where the E-stops are located, and to not stand directly next to the table as the gantry can rapid quickly and collide with the individual.

  • Due a dry run of the program with a large Z offset to ensure the machine will not crash.

  • Make sure that your workpiece is securly held down and the collet is fully tightened.

Machine Operation

Machine Start-Up:

  • Ensure that area around the table is free of objects and that you can walk freely around the entire machine.

  • Turn on the desktop computer and login to the ME02588\me-admin account with password ________

  • Open Mach-3 on the control before starting up the machine.

  • There are 3 E-Stops located on the machine (Side of Gantry, Spindle, and Machine Power Unit). Ensure that all of the E-Stops are pulled out and the machine power unit is turned on.

Mach 3 Control Software

Machine Controller:

  • The machine is run on Mach-3 which is a standard CNC Router platform

  • To move the spindle and gantry, use the arrow keys to move the machine in the desired direction.

    • Pressing the tab key will pull up the MPG screen.

    • This allows a fast, medium, or slow jog rate to be specified as well as a step mode.

    • The step size can be varied to properly set work offsets and tool length.

  • The middle of the screen displays the work offsets. The zero buttons located next to each axis are used to set work offsets on the machine.

  • The bottom middle block of the control displays Tool Information. This block is used to set tool length and tool height.

  • The left side of the control will display your G-code and provide basic machine control buttons including single block, cycle start, feed hold, and stop.

  • The right bottom blocks display feed rate and spindle speed settings. These can be overriden during a cut to adjust cut parameters

Loading Tools:

  • This machine uses ER-16 collets. Three collets (1/4", 3/8", and 1/2") have been purchased for the machine and should be located next to the controller. If other sizes are needed, the respective team should supply them.

  • The collet follows the same procedure as any ER collet system.

    • Take the collet nut off of the spindle

    • Replace collet with desired size and ensure that collet is fully seated in the nut.

    • Turn collet nut onto spindle (~2 turns).

    • Slide tool into collet and fully tighten with two wrenches.

    • NEVER TIGHTEN COLLET WITHOUT A TOOL IN THE SPINDLE

Spindle collet nut and dust boot assembly

Setting Tool Length:

  • Each tool used in a program will need a specified tool length. Since this machine does not have a tool changer, it is best practice to use only one tool per program.

  • Ensure that your CAM tool table numbers match the tool number that is displayed in the control when setting offsets.

  • The easiest way to set the offset is to set the control to T1 and leave the H value set to 0. When setting your Z-offset for the work coordinates, the Z zero should be set off the tip of the tool in your desired location. It is standard to set this value off of the table surface.

    • To set Z zero, lower the tip of the tool close to the table, set the control in a small (~0.005") step size and continuously slide a piece of paper under the tool while lowering until the tool "grabs" the paper. This location should be set to Z zero.

Securing Work Piece:

  • Depending on material and workpiece size, different methods can be used to properly secure the stock to the table

  • If the MDF board on the table has been cut/worn beyond use, clean the top surface then flip the board over to expose a fresh side

    • MDF should be secured to the table with 6 screws around the outside edge

    • Multiple boards are located behind the machine and should be used as replacements

  • Make sure that table is free of debris/dust before loading stock

  • The preferred method is to use hot glue around the perimeter of the stock

    • A hot glue gun and sticks are located under the control computer

    • Apply a bead around the perimeter of the part

    • Typically, hot glue in the middle of the work piece is not required

  • Stock can also be secured by using the screws located next to the machine

    • Ensure that screw locations will not interfere with the cut, as this has the potential to break or chip tools.

Extra spoil boards located behind machine

Setting Work Offsets:

  • Move spindle to desired X and Y position by using the arrow keys and Jog/Step mode on the control

  • Once in desired location, press X Zero and Y Zero on the control to set the work offsets

  • Z-offset should have been set when setting the tool length, but verify Z height

  • Make sure that your work coordinat origin matches what has been programmed in the CAM software!

Running a Cut:

  1. Verify that you have properly secured your work piece, set tool length, and set the proper work coordinate system

  2. Attach the dust collection boot to the underside of the spindle. The dust boot is magnetic and should snap into place.

  3. Turn on the dust collector to the right of the machine by pressing the white button on the front.

  4. Load your program on the controller. Programs should be copied from a flash drive after post processing (Using the Mach 3 Post Processor) to the desktop.

    • NEVER RUN PROGRAMS OFF OF A FLASH DRIVE

  5. Use the open button in Mach 3 to load the program. A visual display should appear on the control

    • Verify that the program is correct by visually inspecting the tool path

  6. Once ready, put the machine in single block and press cycle start

  7. Step through the program until the tool is about to enter the workpiece.

    • Verify that offsets look correct

  8. Turn off single block mode and press cycle start again to begin cutting.

  9. The overrides should be used to adjust cut parameters

  10. Always watch the cut carefully, if the machine or cut errors out, immediately press the E-Stop

  11. After the cut, make sure to clear the work surface, vaccum any dust with the dust collector, and clean up the surrounding area.

Dust collector should always be used during cuts!