Table of Contents

• Overview
• Machine Guides
  • 2nd OP Mill Guide
• Part File(s)
  • Part A
  • Part B

• Material Requirements
• Tool List
  • Part A
  • Part B
• Operations
  • Part A
  • Part B
• Frequently Asked Questions
• Troubleshooting

Overview

These lab instructions are for the CNC Mill 2 2nd OP upgrade and is designed to be accompanied by the relevant machine guide for the upgrade (e.g. CNC Mill 3 - 2nd OP should use the 2nd OP machine guide listed below. If at any point during the training you have any questions please contact staff.

Machine Guides

• 2nd OP Mill Guide

Part Files

• Part A
• Part B

Material Requirements

Parts A & B will be made on the same piece of stock (one on top face, one on bottom face). Tools and GCD file are located in the designated tool box at the machine.

Tool List

Part A

• Pair of 1¼”parallels

• Edge finder

• 6” caliper

• CNC mill 2 part A tooling box

• Tool 1: 1/4" spot drill(Same for both parts)

• Tool 2: #7 drill

• Tool 3: 1/8” drill

• Tool 4: 5/16” 2 flute center cutting end mill

• Tool 5: 3/32” 2 flute center cutting end mill.

Part B

• Pair of 1¼”parallels

• Edge finder

• 6” caliper

• CNC mill 2 part B tooling box

• Tool 1: 1/4" spot drill(Same for both parts)

• Tool 2: 5/32” drill

• Tool 3: 3/8” 2 flute center cutting end mill

• Tool 4: 1/4” 2 flute center cutting end mill

Operations

Part A

1. Refer to 2nd OP Mill Guide to complete operations listed below.
2. Upload program 0031.GCD to the controller, from thumb drive found in the green toolbox dedicated for each machine. At no point should the air blast be used to blow of machine/vices/parts without a tool in the spindle!
3. Secure the tool holding fixture in the vise and mount the tools for the upgrade in the appropriate toolholders. Tools are located in the top left drawer of the green tool box in a box labeled Pr#0031.
   • Note: When using the collet chucks, take the nut off the holder and push the collet into it until it clicks. Screw the nut back on the holder. Place the tool into the collet and use the 1" wrench or a spanner wrench to tighten the nut.
   • NOTE: 2OP 1 you will use a spanner wrench to tighten the nut while 2OP 2 will use the 1" wrench.
4. Set up tool #1 in tool table. Revert to the Setting tools in the tool table link provided.
   • NOTE: Use the .0002 resolution when lowering onto the tool setter and moving away from the tool setter.
5. Now set tool #1 into the ATC. Revert to the instructions in the Loading tools in the ATC link provided.
6. Repeat steps 4 and 5 until all tools are set in the tool table and placed correctly into the ATC.
7. Place a parallel up against each jaw inside the vise.
8. Place the stock on top of the parallels and tighten the stock in the vise.
9. Use the edge finder located in the tool box and set X0,Y0 in the center of the stock.
10. Call up tool 1 from the ATC. Use paper to set Z 0 at the top of the stock with tool 1. NOTE: use the .0002 resolution when lowering tool to set Z 0 and moving it away from the top of the stock.
11. Use tracking at the start of each operation to make sure Z axis for each tool is set correctly.

Part B

1. Refer to 2nd OP Mill Guide to complete operations listed below.
2. Upload program 0032.GCD to the controller, from the thumb drive in the green toolbox dedicated for each machine. At no point should the air blast be used to blow of machine/vices/parts without a tool in the spindle!
3. Secure the tool holding fixture in the vise and mount the tools for the upgrade in the appropriate toolholders. Tools are located in the top left drawer of the green tool box in a box labeled Pr#0032.
   • Note: When using the collet chucks, take the nut off the holder and push the collet into it until it clicks. Screw the nut back on the holder. Place the tool into the collet and use the 1" wrench or a spanner wrench to tighten the nut.
   • NOTE: 2OP 1 you will use a spanner wrench to tighten the nut while 2OP 2 will use the 1" wrench.
4. Set up tools in the tool table and the ATC in order as you did in part A.
   • NOTE: Use the .0002 resolution when lowering onto the tool setter and moving away from the tool setter.
5. Place a parallel up against each jaw inside the vise.
6. Place the stock on top of the parallels and tighten the stock in the vise.
7. Use the edge finder located in the tool box and set X0,Y0 in the center of the stock.
8. Call tool 1 from the ATC. Use paper to set Z 0 at the top of the stock with tool 1. NOTE: Use the .0002 resolution button when lowering the tool to set Z 0 and moving the tool away from the top of the stock.
9. Use tracking at the start of each operation to make sure Z axis for each tool is set correctly.

Frequently Asked Questions

What is TRAKing?

TRAKing allows the user to control the X,Y and Z feed with the use of the hand wheels, located at the front and the right side of the machine! The right side hand wheel is the course feed and the front hand wheel is the fine feed. It is recommended to use TRAKing at the start of every tool change to make sure that the Z offset is set correctly for each tool.

Troubleshooting

Why is my Z offset wrong?

The user may have set the Z offset with the wrong tool. For example; If you set the Z offset with tool 1, the tool # on the DRO needs to be set at tool 1. Most of the time the user will set tool 2 into the tool table and forget to change the tool number back to tool 1 to set the Z offset.

Important information after completing this upgrade- You do not have to have a CAM file or a GCD file to run the 2 OPs. These machines can be used maually as well as conversationally. Please consider using this equipment after you complete the upgrades!