The Milling Machine
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.
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
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.
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.
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.
CNC Speed and Feed Capabilities
Lab Volt 5600
Rapid Traverse Speed – 508 mm/min
– 20 in/min
X Range
-- 178 mm (7 in)
Y Range – 102 mm (4 in)
Z Range -- 203 mm (8 in)
Speed Range – 0 – 3,400 RPM
Lab Volt 5600
Z Axis Stepper Drive Motor
Safety Shield
Cross Slide
Spindle Motor
Spindle Head
X Axis Stepper Drive Motor
Y Axis Stepper Drive Motor
1
2
3
4
5
6
7
1 4
5
2
3
6
7
Manual Control Panel
• Manual Feed Rate
Entry
• Manual Spindle
Speed Entry
• Emergency Stop
• X,Y,Z Axis Manual
Jog
• Digital Control
Screen/Display
Other Vises / Hold Downs Low Profile Clamping Kit
Step Blocks and Strap Clamps 2 Axis Pneumatic Vise
One Axis Pneumatic Vise
Lab Volt 5600 Pneumatic Vise
(One Axis)
Loading / Changing a Quick
Change Collet
• Move the Z axis to a safe
location
• Press the emergency
button
• Open the safety
shield
• Press pin on Easy Change
turn spindle, and remove
tool/collet
Easy Change Spindle
• Press in Pin fully
• Turn Easy Change
Collet to the right
• Remove the tool
• To insert new tool,
align notches with
slots in collet
Pin
Tool/Collet
Spindle
Mill 5 Home Screen
Tool Bar
Starting a New Program
• • Script Program: provides access to the Line Editor for editing a G and M code
part program, one line at a time.
• • Block Part: provides access to the Block Editor for editing blocks of G and M
commands, and setting the parameters required for each G or M command.
Starting a New Program Cont.
• Selecting either
script or block
will open up the
program
information
• Here, information
such as absolute,
or incremental
referencing can
be selected,
along with units
of measurement
and part zero
Machine Zero / Home
+X
-X
+Y
-Y
+Z
-Z
Part Zero
+X
-X
+Y
-Y
+Z
-Z
(0,0,0) PRZ Position
Xp
Zp
Note: x offset = y offset = D/2
z offset= 0
Front View
Work Piece
Part Reference Zero (PRZ) Position
Xp
Yp
Part Reference Zero (PRZ) Position
D= tool diameter
(0,0,0) PRZ Position
Work Piece
Xm
Ym
Machine Axes
Part Axes - y offset = D/2
Top View
- x offset = D/2
Cutting Tool
Part Reference Zero (PRZ) Position
• This feature is
allows the software
and mill to know
what size material
will be cut.
• For example, by
typing in Z+,0 and
Z-,-0.5, the
software knows the
part reference zero
is on the top, and
the material is .5
inches thick.
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.
CNC Machine Axes
-X
+X
-Y
-Z
+Z
+Y
PRZ
– Part Reference
Zero
– Origin
– 0,0,0
Environment Setup
Environment Setup
allows you to Change
the language the
software runs in,
specify the folder in
which new part
programs are saved,
and edit the default
foreground and
background colors
used for the Line
Editor display.
Machine Setup
• This feature
allows you to
choose how
the software
communicates
with the mill
through the
desired Serial
Port
Advanced Mill Setup
• This feature
allows
changes to
the tool size
to be used in
the 3D
rendering
Tool Table
• This feature
sets up the
actual tool
used for the
program,
including bit
diameter,
nose type,
and offset
Materials Setup
• This feature
allows you
to select the
material to
be cut and
the feed
rate and
speed rates
for cutting
Rendering
• Allows
changes to
be made
which are
viewed in
the 3D
rendering
Emulation Screen
-The emulation screen
allows the program to
be previewed, showing
an animation of all
toolpaths, and a view of
the finished product.
-Changes can be made
to the program after
viewing the emulation,
such as tool selection,
depth of cut, and
spacing of designs