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--- haas_super_mini_mill_training_sop [2020/09/28 16:20] – created furst
+++ haas_super_mini_mill_training_sop [2023/01/05 02:36] (current) – [Haas Super Mini Mill Training SOP] haley
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 ======Haas Super Mini Mill Training SOP======
-Last edited: Furst (09/28/20)
+Last edited 1/4/23 Haley
 Instructor: \\
@@ Line 99: / Line 99: @@
     - Post the code by selecting Post Process and selecting Carbide 3D (grbl) as the post configuration. The program name or number should be numbers only, and is typically notated 00001 (not necessary for carbide but good practice for larger machines) make sure to select the desired output folder as by default Solidworks buries the G-code
-====Setting up the ShopBot for a Job:====
+====Setting up the Haas Mill for a Job:====
-The ShopBot router uses slightly less puny ER20 collets to hold tools from .04" to .511" but typically uses tools with a 1/8, 3/16,1/4 or 1/2 inch shank.
+The Haas CNC mill uses big boy CT 40 taper tools to hold anything from ER 32 collets to drill chucks and work piece probes. Gripping range is basically anything you can imagine machine with this tool all the way up to 1" shanks. Tool 1 is typically set up with a 1/2" endmills and tool 8 with a Renishaw tool probe.
 **Changing tools:**
-  - Turn the router off and using an acid brush remove metal shavings and any dust from the tool and collect
+  - Select MDI mode by pressing the MDI/DNC button once
-  - Using the large open wrench on the spindle shaft flats and the spanner on the collet nut, loosen the collet and tool.
+  - Using the ATC forward and ATC reverse buttons bring the desired tool into the spindle
-  - Unscrewing the nut all the way allows the collet and tool to be removed from the spindle and changed out with a different tool of the same shank diameter or with a different sized collet.
+  - HOLDING THE TOOL HOLDER that is in the spindle press the ATC release button or the black button located on the machine head inside the machine
-  - Separating the collet from the collet nut can be done by pushing on the back end of the collet so that it becomes angled within the retaining collet nut and then can be pulled out.
+  - The tool should release with an accompanied air purge to clean the spindle tapers
-  - Before reinstalling the new collet and tool, wipe down the tool shank as well as the collet and spindle tapper.
+  - Using the CAT 40 tool tightening fixture in a vice, secure the tool holder insuring to close the lever containing the second spindle dog
+  - Using a spanner or a box wrench carefully loosen the collet nut or tool clamping mechanism
+  - Before replacing the cutting tool insure all collet tapers and tool shanks are clean and free from dust or chips. Wipe with a clean paper towel before installing
+  - Using the correct spanner or box wrench carefully and firmly tighten the collet nut or retaining mechanism.
+  - Check the pullstud with an open ended wrench and insure that it is snug within the Cat 40 tool holder
+  - Pressing and holding the ATC release button or black button on the head of the Haas insert the tool holder into the spindle making sure to align the spindle dogs with the tool holder before releasing the button.
 **Homing and Zeroing the machine:**
-  - With the tool installed, make sure the bed is empty and the doors are closed before turning on the machine. The switch on the front of the machine should turn it on, however there are two different interlocks, one on the back of the machine which controls master power, and one on the hand unit which need a key before the machine will move.
+  -
-  - Launch ShopBot 3 from the laser cutter computer
-  - Select the X,Y table button from the red position window to send the machine to its home position
-  - With the tool in the spindle, attach the grouping clamp to the tool shank or the spindle, and place the aluminum electrode on top of stock you wish to cut. Jog the tool to be above the electrode. Check that as the tool and electrode come in contact that output one lights up. Select the Z button from the same position window and the machine will automatically zero out the tool height then retract to 1/2" above the surface.
-  - Next select the yellow keypad to move the spindle to find part zero broad movements can be made using the arrows, fine adjustment can be made by pressing the "Fixed" button and entering a jog distance per click.
-    - An edge finder can be used at the minimum RPM to find the part X and Y zero by jogging using the virtual keypad. Offset the axis by the radius of the edge finder, and switch the console to advanced mode. Under the zero drop down select X or Y zero to set part zero. The cutting tool can then be replaced in the spindle and re-zeroed using the automatic tool length touch off.
-    - An alternative but fastest way to establish part zero is by using a piece of paper or shim and slowly jogging the axis towards the part until slight resistance is felt on the paper or shim used. The part zero can then be set after offsetting X and Y by the radius of the tool plus shim thickness, and the Z axis by shim thickness.
 **Starting Job:**
-  - Load the desired G-code using the File drop down and selecting "load new file"
+  -
-  - Make sure drawing zero matches machine part zero
-  - Start Job
 ====Machine Limitations====
-  * Each tool change should be accompanied by a new job within HSM Works
+  *
-  * Tool shank diameter is limited to 13 mm
-  * Max stepdown is limited to .05" in metal and .1" in wood
-  * Work area is limited to 24" x 18" x 3.5" x,y,z
 ====Choosing tools====
-Many tools are optimized for different materials, and although a 2 flute endmill can do most operations, it is not always ideal. Single and duel high helix endmills are available for plastics, woods, and composites, with carbide endmills and burs available for abrasive materials like glass fiber reinforced materials such as circuit boards.
+Many tools are optimized for different materials, and although a 2 flute endmill can do most operations, it is not always ideal. Single and duel flute high helix endmills are available for plastics, woods, and composites, with carbide endmills and burs available for abrasive materials like glass fiber reinforced materials such as circuit boards.
-Feeds and speeds can be found {{ :tools:shopbotcncrouter:feedsandspeeds.pdf |HERE}}
+Feeds and speeds can be found {{  |HERE}}
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 -----
-=====Shopbot Desktop Quick Review=====
+=====Haas Super Mini Mill Quick Review=====
 Tool Lead: Andrew Furst \\
 Contact: Andrewfurst@ucsb.edu
 ====Safety Concerns====
   * Safety Glasses must be worn when machine is running
-  * The acrylic doors must be closed before starting a job
+  * The glass door must be closed before starting a job
   * The spindle must be completely stopped before adjusting or removing work piece
   * After milling is completed, the work piece will have developed sharp burrs which must be removed with a hand file or sandpaper
-====Safe Operating Procedures Review====
+===== Operating Procedures Review =====
-  - Design part using Solidworks or other CAD platform
+  - Program tool paths using a SOLIDWORKS add-in
-  - Using HSM Works generate tool paths
+  - Put tools in tool holders
-    - Each different tool needs to be a separate job as only one tool can be loaded into the Shopbot at a time
+  - Set tool offsets using tool probe
-    - Use 2D and 3D clearing and pocketing to remove the bulk of the material while using "stock to leave" to allow for a finishing pass
+  - Set fixture offset(s) with touch probe (usually G54)
-    - Simulate the toolpaths to verify that the tool will not crash and is cutting in the desired location
+  - Load program
-  - Using the open ended wrench on the spindle flats and the spanner on the collet nut to change out the tool or collet itself if switching shank diameter
+  - Check that tool numbers in program match tools in machine
-  - Home the machine and zero the tool using Shopbot 3, set part zero using the yellow keypad and slowly jogging the tool or edge finder to the part. DO NOT FORGET TO ADD OFFSET OF TOOL RADIUS AND SHIM THCINESS
+  - Check that appropriate fixture offset is loaded
-  - Upload the G-Code into Shopbot 3 under File-> Load
+  - Load stock in the machine
-  - Start program
+  - Proof the part (test the program with air cuts). One easy way to do this is to add a height to the G54 Z value sufficient to make sure that all cuts will be above the top of the part surface.
+  - Use rapid and feed override at the beginning of the program to make sure that the initial Z axis moves are safe. You can also use single block mode
+  - Keep your hand close to the emergency stop in case the program doesn’t do what you expect.
+  - Reset G54 to the correct value.
+  - Run the program for the first time - follow the precautions in step 10 to make sure that nothing unexpected happens. You can adjust the feed rate override as needed.
 ====Post Processing====