Typical CAD/CAM CNC Mill Project Procedure

For a fuller description with illustrations, visit

http://techweb.bsu.edu/jcflowers1/rlo/rpMill.htm
(updated February 6, 2017)

A. Design the Part: CAD

1. Determine machine limitations.

2. Determine cutting tool limitations.

3. Determine stock limitations.

4. Open AutoCAD.

5. If you will be milling from a rectangular prism, begin with a rectangle of the
stock's width and depth. Use the "right hand rule" for determining axes and
directions.

6. Draw geometry that will later be used to create toolpaths. Please realize that you
are not drawing a picture of the final object because the tools used in the milling
machine have a particular width and end geometry, and they may not be able to
mill out the image you are creating.

7. Show your design to the instructor or lab supervisor for approval.

8. Save the AutoCAD file in its native format on your own removable medium. If
you were asked to use a file-naming protocol, please do so. Next, use the Save As
command and select Other Formats, then select AutoCAD 12 dxf.

9. Once the design is approved, cut your stock to size. Follow all safety guidelines
for this, and if you need help or instruction, ask the instructor or lab supervisor.

B. Identify the Toolpaths and Parameters to Create the NC Code

10. On one of the computers controlling a milling machine in AT 136, open

SpectraCAM Milling and open your dxf file. These, and the instructor's computer in
AT 130, are the only machines containing this software.

11. Under Setup, specify the correct:

Material Type (for wood, use the Machinable Wax setting)

Tool
Stock Size

12. Think through the operations and determine their sequence.

13. For each operation, select the appropriate operation type:

1
 Contour
Face
Engrave
Drill
Swept
Ruled
Surface of Revolution
14. Click the Setup button at the top left of the screen.

15. Specify the critical parameters of the cut. Most important is the "Z Final"
amount.

16. Select the geometry.

17. Click the "Go!" button, then accept the tool paths.

18. Remember to re-set the parameters for each machining operation.

C. Verify the Code

19. Use any computer that has CNCBase for ProLight 1000 Machining Center
program or the Benchman MX control program; these two are essentially identical.
Open that program, and open your NC file within that program.

20. If the NC code screen has a grey background, click Edit, Lock, to unlock it if
necessary.

21. Click Tools, Select Tool, and select the appropriate tool. If it is not available,
add it to the library and then select it.

22. Click the red Verify button. Click Verify Options and then make sure that the
stock size, origin, and initial tool position are correct. Change the

23. Fix the program as necessary.

D. Prepare the Mill

24. Safety glasses are required in AT 136. Turn on the Benchman MX milling
machine. If you are using the Prolight 1000 Milling Machine, be sure to turn on its
power supply / controller box.

25. Engage the red emergence stop button by pressing it in.

26. Secure your workpiece to the table, possibly using the precision vise.

27. Install the correct tool.

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 28. Close the door/cover. Disengage the emergency stop.

E. Prepare the CNCBase Software Environment

29. Select Tools, Select Tool, and then select the correct tool for this job. If it is not
there, you might need to add it to the list and then select it.

30. Select Setup, Set/Check Home, and click Home.

F. Establish Known Coordinates

33. Establish the Z coordinate:

a. Use the Jog Control window or the keyboard to move the tool. Move the
tool so it is in the center of the stock but slightly above it.

b. Open the door to the Benchman.

c. Use a piece of office paper as a feeler gage, and move the tool down
.001" at a time until it just touches the paper. The paper should still slide,
but with some resistance.

d. Right click on the Machine Info window and select Set Position.

e. Enter the position of the tool along the Z axis. If the top of your stock is at
Z0, and the paper is .004" thick, you would enter a positive .004 as the Z
position. All of your machining would be in the Z negative range.

f. Move the tool up to about .1" above the stock so you can later move it to
find the X and Y coordinates without scratching the stock.

34. Establish the X and Y coordinates

a. Move the tool so that the very center of the tool is directly over the front,
left corner of the block.

b. Assuming this is X0 Y0, right click on the coordinates in the Machine Info
window, select Set Position. (Do not click Zero Position because this would
lose the value of the Z axis.)

c. Type in the value of 0 for each the X and Y positions. Click OK.

35. Close the door and make sure it latches.

36. Move the tool to the starting position. You can do this by right clicking on the
Machine Info window and then clicking Go To. Type in the coordinates of the
starting position and double check these. If you flip any positions, make a mistake

3
 with plusses and minuses, or leave out a decimal place, the tool could crash into
the vise and break. When you are sure the coordinates are accurate and the path
to them is clear, click Go Rapid.

G. Make Final Preparations

37. Verify the code one more time and save the verified version.

38. Make sure that "Single Step" is not selected in the run parameters.

39. Check again to make sure the tool is held securely, the stock is held securely,
and both the spindle wrench and the spindle lock cylinder have been removed.

40. Make sure the door is closed and latched, the emergency stop is disengaged,
and the override control dials are near their center positions.

41. Make sure the readout of the coordinates on the screen matches where the
tool is.

42. Make sure that you and everyone around you is wearing safety glasses.

43. Get the lab supervisors approval to machine before you run the program for
your first time.

H. Run the Program, Clean Up & Power Down

44. If you have received the lab supervisor's permission and you are confident in
your work, then click on the green Run button. There may be two built-in delays
that require keyboard action, so take that action.

45. While the part is machining, stay with it and monitor it; your hand should be on
the Red Emergency Stop button for the first time you run the part. If anything goes
wrong, like the stock coming out of the vise or the tool heading in the wrong
direction, press the emergency stop button. There are two additional emergency
stop icons on the software that function in the same way.

46. When the milling machine has come to a complete stop at the very end of your
program, press in the Red Emergency Stop button, lift the cover, and remove your
part. Repeat as needed for additional parts.

47. When you are done for the day, please clean the lathe. Vacuum out the debris. Put all
tools and materials away. Power-down the computer and the mill.

4
 (NC Mill TRACE1):
N1G90G0X0Y0Z.1;HOME
N2M03;TURN ON SPINDLE
N3X0.5Y2.1
N4G1Z-0.1F2
N5X0.3
N6Y2.8
N7X.5
N8G2X.5Y2.5I.5J2.65
N9G1X.3
N10X.5
N11G2X.5Y2.1I.5J2.3
N12G0Z.1
N13X.95Y1.65
N14G1Z-.1
N15G3X.8Y1.5I.8J1.65
N16G2X.6Y1.3I.8J1.3
N17G0Z.1
N18X.8Y.8
N19G1Z-.1
N20Y.4
N21G3X1.2Y.4I1J.4
N22G1Y.8
N23G0Z.1
N24X0Y0
N25M02;END OF PROGRAM

5
N1; MP1 1/8" end mill, 3x2x1" Mill Practice: Draw the exact design that
N2G90G0X0Y0Z0; wax would be cut into the top of each block. The
N3G0Z.1 tool begins at the top, front, left of the block.
N4M3S2000G0X1Y1.2
N5G1Z-.1F5
N6Z-.05F3
N7X1.5
N8Y.5Z-.2
N9G2X2.1Y1.1I2.1J.5
N10G1X2Y1.5Z.05
N11M5G0X0Y0
N12Z0
N13M2

N1; MP2 1/8" end mill, 3x2x1" wax

N2G91G0Z.1M3S2000
N3G0X.2Y.1
N4G1Y.2Z-.2F5
N5Z-.05
N6X.8
N7Y.5
N8X.5Y.6
N9Z.1
N10G2X0Y-1I0J-.5
N11Y1J.5
N12G0Z.1
N13G0X0Y0
N14G1Z-.2
N15Z0
N16M2

N1; MP3 1/8" end mill, 3x2x1" wax

N2G90G0X0Y0Z0
N3M3S2000G0Z.1
N4G4F3
N5G0X1Y.5
N6G1Z-.1F2
N7G91
N8G1X1
N9X-1Y1Z.2
N10Z-.15
N11G2Y-1J-.5
N12X.5Y.5I.5
N13G90G0Z.1
N14M5G0X0Y0
N15M2