so you want to get to know Onsrud... Onsrud1 : machine set up

so you want to get to know Onsrud... Onsrud1 : machine set up

What does CNC mean? CNC: Computer Numerical Control The router is controlled by a computer, that tells the router where to go through a series of basic commands, known as G-code. G-code is produced in Mastercam, and is saved in a.nc file. Here you will see the tools used in your file, X,Y, and Z coordinates, and other commands such as GOO (machine rapid move) and G01 (Feed) that tell the machine how to move between the coordinates. Now that you know how the Onsrud works, let s set it up! ;*** TOOL LIST *** ; TOOL - 01 DIA. -.375 3/8 STRAIGHT BIT ;***************** N100 G92Y(@YAXG92) N110 G16XY N120 G00 G79 Z(@ZPARKP1) N130 G500 T8 F8 ;( TOOL - 01 ) N160 M06 T1 N170 M03 S20000 N180 G00 X37.0556 Y-.0059 N190 Z3.25 N200 G01 Z.0037 F300. What does CNC mean?

1. power up computer and log on! power to comupter turn on! * just press ok! The program OSAI Process controller will start automatically. In the event that it does not, just double click on Boot Control to launch the program.

2. turning on Onsrud turn drives on Onsrud should be left in the emergency stop at all times when it is not being used. When the computer logs in, the program will have this message: 001 MACHINE IN E-STOP Pull out the emergency stop button and turn drives on to boot up the onsrud.

the router often has existential crises and must re-discover its true meaning in life. Press auto home to help Onsrud locate 0,0,0 and go home. 3. auto-home. AUTO-HOME

4. warming up the machine RESET GO STOP * Level up and learn your GCode: M6: Tool change T1: Tool 1 MDI: manual data imput MDI is a mode where you can directly write NC code to tell the router what to do. Select MDI and a dialogue box will appear. Type in M6T1 in all caps. Hit enter, and then press GO. Then type in M3S9000, press enter and GO to warm it up for ~5 minutes. After 5 minutes, press stop, and reset. (if someone has recently used the router, you can skip this step) M3: Spindle rotate clockwise S9000: spin at a rate of 9,000

Tools come in all different shapes and sizes... 5. get familiar with your tools in addition to tools coming in a variety of sizes (1/8, 1/4, 3/8 and 1/2 ) tools have different shapes for what they are cutting. Straight flute: cuts hard or abraisive materials, very durable Compression Spiral: Optimum edge finish on both sides of laminated materials, veneered and natural wood composites. Designed for low-speed applications. Four flute: feeds twice as fast as two-flute end mills, good for finish cuts Two flute: two flutes maximize chip clearance, good for rough cuts

6. understanding the tools mill: part actually cutting the material. Can come in different diameters, amouts of flutes and round or flat ends The collet goes into the collet nut before it is screwed onto the chuck. Let me say that again: THE COLLET GOES INTO THE COLLET NUT. If it is shoved into the chuck, it can become stuck and both chuck and collet become useless. shank: part of the tool that the collet holds, often has a different diameter from the mill length of cut: NOT length of tool, length of how much the tool can actually cut collet nut collet chuck

1. 2. step 1: the collet goes into the collet nut. Put it in at a 45, and then apply a small amount of pressure until it clicks in. it should spin freely. * 3. protip: right-y tight-y, left-y loose-y step 2: screw on collet nut onto chuck and place tool in hole step 3: place assembled tool into holder to the left of the computer and use this tool to tighten. 7. putting your tool together

8. measure your tools Place collet in the slot and move the arm down, until it gently touches the end of the tool. Record measurement to the thousanth place. Turn on. Press zero/abs when the arm is all the way down, to ensure an accurate reading. Subtract.04 to the measurement to account for the little lip

9. tell Onsrud how long the tool is Look in the upper-left hand corner of the screen. There is a symbol that looks like a graph with a cyan colored line through it. Click on it. you will be taken to another screen. Click on tables, and then offset.

tell Onsrud how long the tool is pt.2 10. you will be presented with all the tool numbers and lengths that Onsrud has stored. double-click on the tools you want to change and adjust the length, making sure they correspond with the appropriate tool number. when you re done, press ok and close the window.

11. loading your tool go to tool setup in the bottom right hand corner of the main screen. click on tool tray in to take the tool tray out (it s backwards... just go with it) place your tool in the appropriate slot, it shouldn t need more than a good push.

12. Loading your program Put your file on a usb stick. Minimize the program (OSAI Process Controller). Drag your.nc file from the usb to the UPP folder. Open the program and click on Part Program --> Part Program Management Deactivate any previous program. Find your file, and press activate.

double check that your file has loaded and has done so correctly. Things to look for: correct file name, tools, and order of tool changes. 13. table mode and file check make sure that table mode is set to XU LOCKED. Each of the tables are 5 x5, one of which is X and the other is U. If they are not locked, they will move independently of each other - which could or could not be what you want.

14. compressors and dust collection system Go to the back room of the woodshop and turn on the dust collection system (black box on the wall) if it is not already on. Press Start and make sure it says RUN < 36.00 HZ This will make sure that the debris from routing is sucked up instead of going into your lungs. Turn on the compressor (the big yellow box) by pressing the green button. It should make a loud noise when you turn it on, so don t be alarmed. Now you can turn on the vacuum to the table to keep your material in place when you re routing.

The table considers x axis to be the short end.make sure your material is oriented correctly so you don t have to make a midnight trip back to Lowe s. Y * (0,0,0) X Now that you ve set up your material, cover the rest of the table with scrap material. This will help the vacuum hold down your piece and prevent wasted energy. Keep in mind, if your piece is smaller than 5 x5, you only have to turn on one table, so you don t have to cover both of them. Now you can press the yellow button under the table to turn the vacuum on. 15. table

* press me! Use duct tape to tape the sides of your piece and to fill any holes that may be sucking in air. this should no longer be at zero Check to make sure your material is solidly placed by trying to push on it. Keep in mind that the vacuum table works great against lateral movement, but is very weak if you pick your pice up vertically. 16. vacuum

Be careful: if at any time you touch the red emergency cord around the router, or red band around the table, it will go into emergency stop. What does this mean for my project? It means that you have to write down at least three lines of G-Code where it stopped before pressing Drives On and resetting the machine. Pull out the little blue pin here to reset the emergency trip cord. You should be able to see the green part. 17. E-stop

E-stop and stop: Know the difference If you simply wish to stop the onsrud, but there is no apparent danger, press stop. This way, if you wish to resume, you can press stop and GO again, and the router will resume in the same place. 18. STOP Before you route EMERGENCY STOP However, if there is some emergency, press the big EMERGENCY STOP button located next to the computer screen. This is essentially the same as touching the red emergency cord. This stops your file and you must press Drives On and reset before you can start your file completly over.

19. Retract Z: You can only access this after the machine has been stopped and reset. This will retract the Z axis to the Park Position. It is imperative that you do this if you see a fire, to allow better axis to the material. Table Load: Once and only once you have retracted the Z, you can table load so that you have better access to the table to place your material. Brushes Up/Down: This allows you to move the dust brushes up and down to better see the end mill and material. Auto Home: sets X,Y, and Z positions and absolute zero. Do not run the machine before doing this! Before you route: Helpful buttons

20. If you click on tool setup on the previous page, it will take to you these sets of controls which are a little more specific. You will recognize: Z axis retract, Table Load, and Brushes Up/Down. You will also be able to access: Tool Tray In/Out: You can move the tool tray out by pressing Tool Tray In and can place your tools in the slots. Return: Returns back to main Process Control Screen Helpful buttons pt. 2

Is there a fire? If you smell smoke or suspect a fire but are unsure, press stop and Brushes Up to check and see - If there isn t a problem, press stop and GO to resume. If there is a fire: DO NOT PRESS EMERGENCY STOP. It will stop Onsrud and block access to the fire. Instead, press stop, reset, and retract Z. This will get the tool out of the way for you to put the fire out. Turn off the vacuum - the vacuum table works by sucking air through your material. Cutting off the air will mean cutting off fuel to a fire. Is there a flame? The fire extinguisher is located next to the door. Simply pull out the pin, aim, and squeeze the lever. You ll have ~20 seconds of awesome extinguishing power before the foam runs out 21. Be prepared for a fire

switch into AUTO mode you may now press GO. (be sure to click brushes up after it begins to make sure it isn t plunging into the table...) 22. begin!

Putting the router away: Stop. Reset. Park tool. Turn vacuum table off, as well as the compressor. Clean up after yourself, we don t have a cleaning service. Place machine into emergency stop and shut down the computer like a normal computer. Turn power switch to computer off. Congratulations. You have successfully routed something. 23. cleanup

When you stop your job, move your mouse from Brushes Up/Down, around Table Load and press Retract Z first. You don t want to accidentally hit Table Load when the end mill is still in your material. This will break the end mill and you will owe the school lots of $$. Sadface. 24. helpful tricks

25. level up Flip Milling Tips Method 1: Make sure you have a straight edge on both sides so you can line it up with the edge of the bed. Hope it works. Method 2: Drill four points in the corners of your material, ~1 away from the edges -.25 into the bed. This way, you can use dowels to line up your project after you ve flipped it over. Be sure not to lose these along the way in your Rhino and Mastercam file - they are the key to having a piece lined up.

26. level up again Deleting G-Code So something moved and you had to press stop before the router messed up your entire piece. If for any reason you need to press stop in the middle of a job, before you press reset, write down at least three lines of code. After you press reset, the place where you were in your file will be lost so make sure that s what you want to do before you press reset. Go to your G-Code. Use Ctrl-F to find the first line that you wrote down. You can delete everything before that except: Tool numbers. X, Y, and Z G00 (machine rapid move) and G01 (feed move) If it is going to plunge, make sure the first Z is at least.01 higher so that it has a place to plunge from. NEXT -->

;MSAMPLE ;DATE - JUL. 05 2012 ;*** TOOL LIST *** ; TOOL - 08 DIA. -.375 3/8 STRAIGHT BIT ;***************** N100 G92Y(@YAXG92) N110 G16XY N120 G00 G79 Z(@ZPARKP1) N130 G500 T8 F8 N140 G70 N150 (UAO,1) ;( TOOL - 08 ) N160 M06 T8 N170 M03 S20000 N180 G00 X2.165 Y14.4685 N190 Z3.25 N200 G01 Z0. F250. N210 X2.1782 Z.0134 F500. N220 G00 Z3.25 N230 X2.4882 Y14.5678 N240 G01 Z0. F250. N250 X2.4435 Z.0388 F500. 27. level up again_2 new code old code Let s say this is my G-Code, and I stopped the file at: N7510 X.8432 Y2.6461 N7520 G01 Z2.109 F250. N7530 X1.1243 Z2.1036 F500. etc... I control F to find that in my file and make sure I have a new X, Y, and Z and delete everything before it, making sure that I have... ;( TOOL - 08 ) N160 M06 T8 N170 M03 S20000 N180 G00 X2.165 Y14.4685 N190 Z3.26 N200 G01 Z3.25 F250. N7510 X.8432 Y2.6461 N7520 G01 Z2.109 F250. N7530 X1.1243 Z2.1036 F500. N7540 X1.4227 Z2.0983 N7550 X1.5528 Z2.0962 An X, Y, and Z from the new code Changed the Z from 0 to 3.25 so that it won t run the drill through your piece getting to the new XYZ Changed the other Z to 3.26 so it will have somewhere to plunge from. A G00 and G01 before the new code