CNC Mill. CNC Technology prolight Machining Center. Teacher s Guide

CNC Mill CNC Technology prolight Machining Center Teacher s Guide

CNC Mill CNC Technology prolight Machining Center Teacher s Guide 1997 Light Machines Corporation Manchester, NH, U.S.A. January, 1998 and Intelitek 34-7548-0000

1998 Light Machines Corporation All Rights Reserved. The information contained in this guide was accurate at the time of its printing. Light Machines Corporation reserves the right to change specifications and operational performance of its products without notice. Any changes or corrections to the information contained in this publication will be incorporated in future issues. This publication (34-7548-0000, January 1998) corresponds to the prolight Machining Center packages, including the WPLM1000 control software. Printed in U.S.A. spectracam and spectracad are trademarks of Light Machines Corporation. All other register marks or trademarks are of their respective holders.

WARNING The operation of rotating machinery should only be attempted by experienced, knowledgeable individuals! Read the entire contents of the Safety Section before running NC programs on the Machining Center. To avoid possible injury always observe the safety precautions described in this Activites Guide.

Table of Contents Introduction Installation Pre-Test Worksheets Post Test Answers About this Program... i About SCANS Skills... ii SCANS Skills in this Program... iii About the Teklink Activities Book... iv About the Milling Teklink... 1-1 Hardware Installation... 1-4 Installing the Control Program (Software)... 1-8 Safety Checklist... 1-10 Pre-Test... 2-1 Pre-Test Answer Sheet... 2-5 Worksheets... 3-1 Post Test... 4-1 Post Test Answer Sheet... 4-8 Pre-Test Answers... 5-1 Activity 1 Answers... 5-2 Activity 2 Answers... 5-3 Activity 3 Answers... 5-7 Activity 4 Answers... 5-9 Activity 5 Answers... 5-10 Activity 6 Answers... 5-11 Activity 7 Answers... 5-12 Activity 8 Answers... 5-14 Activity 9 Answers... 5-16 Activity 10 Answers... 5-18 Teacher s Guide i CNC Technology: 9801 prolight Mill

Activity 11 Answers... 5-22 Activity 12 Answers... 5-27 Activity 13 Answers... 5-33 Activity 14 Answers... 5-35 Activity 15 Answers... 5-37 Post Test Answers... 5-43 Teacher's Guide ii CNC Technology: 9801 prolight Mill

Introduction About this Program This manufacturing technology program is a flexible, four-semester course of study, based on hands-on activities. It is designed to provide students with a broad base of competencies in modern manufacturing technology. The curriculum systematically covers milling and computer numerical control (CNC), allowing students to acquire the knowledge and skills greatly needed for success in industry. Students work in teams and are exposed to various core technologies on a rotation basis. This concept enables the program to be tailored to the needs of each class and student. By rotating through individual teklinks, students master the technical skills and procedural techniques necessary for competent operation of each piece of equipment. Once the students are comfortable with the basics, design projects emphasize and develop the need to combine teklinks to form islands of automation, or Flexible Manufacturing Systems (FMS). Ultimately, students will be exposed to Computer Integrated Manufacturing (CIM) systems, where they need to complete a project, from concept, through design and all the way to production. Teacher s Guide i CNC Technology: 9801 prolight Mill

About SCANS Skills In 1990 the United States Secretary of Labor appointed a group called the Secretary s Commission on Achieving Necessary Skills (SCANS) to determine the skills necessary to succeed in the workforce. The Commission was composed of 30 representatives of education, business, labor, and state government and was charged with defining a common core of skills that constitute job readiness in the current economic environment. The environment being one of fierce economic competition, new technologies, and rapidly changing skill requirements. Specifically, the Commission was asked to: w Define the skills needed for employment. w Propose acceptable levels of proficiency. w Suggest effective ways to assess proficiency. w Develop a dissemination strategy for the nation s schools, businesses, and homes. During the course of its work, SCANS produced several publications. The Commission s first report, What Work Requires of Schools, resulted from extensive meetings and discussions with a variety of organizations including business, industry, public employers, and unions. The report identified 36 workplace skills that high-performance workplaces require, and that high-performance schools should produce. These skills were divided into a Three-Part Foundation and the Five Competencies. The Three-Part Foundation includes: w Basic Skills, which include literacy and computational skills w Thinking Skills, described as necessary to put knowledge to work w Personal ualities, described as making workers dedicated and trustworthy The Five Competencies include: w The ability to manage resources w The Interpersonal Skills necessary to work amicably and productively with others w The ability to acquire and use information w Skills needed to master complex systems w Skills needed to work with technology It was the finding of the Commission that these skills lie at the heart of job performance and are essential preparation for all students, both those going directly to work and those planning further education. The Commission found that the most effective way of learning skills is in context, teaching learning objectives within a real environment. They also believe that the SCANS foundation and competencies should be taught and understood in an integrated fashion that reflects the workplace contexts in which they are applied. Source: ScansLink: The National Scan Skills Concern, Get the Facts. http://144.162.10.248/ nlc/misc/scans/facts.htm Teacher s Guide ii CNC Technology: 9801 prolight Mill

SCANS Skills in this Program The manufacturing technology program has been designed in recognition of the findings of the Secretary s Commission on Achieving Necessary Skills. The activities enable students to develop and reinforce both technical, occupational skills and the general (SCANS) skills which are required by all people, in any job or educational environment. Tasks enhance problem solving and decision making skills. Cooperative learning and team work promote interpersonal and leadership skills. Projects emphasize information and communication skills. Acquiring these skills will prepare students to successfully meet the social, economic and technological challenges of the 21st century. Teacher s Guide iii CNC Technology: 9801 prolight Mill

About the Teklink Activities Book The Teklink Activities Book is a lab manual which contains 15 Activities, each of which can be completed in one 45-minute lab session. Each activity begins with several lists: w Objectives are the goals students will achieve. w SCANS Skills are the competencies students will develop. w Materials are the specific items needed for each activity. The Overview section introduces the students to the subjects which will be explored in each activity. The Procedures contain series of Tasks, or operations. The first time an operation is to be performed, instructions are given in a tutorial manner. In subsequent tasks students should be able to perform these operations without guidance. uestions and tables for entering lab results appear within the tasks. uestions for discussion and review conclude each activity. All questions and tables are printed on a set of Worksheets supplied with this book. Students should record their answers on the worksheets, or as directed by the instructor. The Academics section at the end of each activity contains enrichment material, such as industrial applications and opportunities, or the scientific background upon which the technology is based. In activities which include hardware (e.g., vise, tooling), students will be directed to perform inventory and safety checks at the beginning of every working session, and to shut down the system properly at the end of each activity. In activities which utilize software, it is assumed that students are familiar with the PC and are comfortable working in the Windows/DOS operating environment. However, instructions for operating the software are explicit and can be performed by novices. Teacher s Guide iv CNC Technology: 9801 prolight Mill

Installation About the Milling Teklink The prolight Machining Center The prolight Machining Center is a three-axis tabletop milling machine which you can run directly from your personal computer. The prolight Control Program, which you load onto your computer, accepts standard EIA RS-274D G&M codes that CNC machine tools recognize. The machining center and Milling teklink are designed to give students an introduction to Computer Numeric Control (CNC) by combining an easy to use interface with a basic benchtop vertical mill. The Mill Teklink contains the following elements: w w w w w w The prolight vertical mill Computer and Controller box WPLM Control Program software for Windows A number of simple NC programs for students to run A mechanical Vise to secure the workpiece to the cross slide Several 3 x2 x1.5 machinable wax workpieces WPLM Control Program for Windows The prolight Control Program provides a simple to use graphical user interface to the machining center. Using colorful graphics and on line help, basic milling operations are easily executed. The prolight Control Program is shipped on two 3.5, 1.4MB disks. It must be installed on the hard drive of your computer, running either Windows 95, or Windows NT version 3.51 (or higher). You must have at least 5MB of free space on your hard drive to perform this installation. Teacher s Guide Installation CNC Technology: 9801 1-1 prolight Mill

Materials Required for the Activities The following materials are supplied with the Machining Center, and are required for the milling teklink. In addition, students may also need a diskette or personal directory on the computer hard drive to store their files. w w w w w w w w w Vise and hardware 2 End Mill Holders 3/8 shank 1 End Mill Holder 1/8 shank End Mill 1/4 HSS End Mill 1/8 HSS End Mill 3/16 HSS 5/32 Hex Key 3/32 Hex Key 3 x2 x1.5 Machinable Wax Workpiece - 2 per student Teklink Requirements Computer Requirements: w Windows 95. w w w w w w 16MB RAM minimum for Windows 95 (24MB is recommended for best performance). A 3.5 in floppy drive. A hard drive with at least 5MB of available space. A full length ISA bus slot to install the interface card. A VGA graphics controller and monitor. A Microsoft-compatible mouse. Lab Requirements: w w A sturdy table or bench for the Machining Center and computer. Placing the table against a wall provides more stability. A 120VAC, 15 amp polarized outlet. Teacher s Guide Installation CNC Technology: 9801 1-2 prolight Mill

Check Your Shipment The first thing you should do after receiving your Machining Center is inspect the packaging for any visible signs of damage. If there is damage to the outside of the packaging, contact the shipping company as well as Light Machines Corp. If there is no damage, locate the packing slip. This slip lists all of the items you should have received with your Machining Center. Check all of the items on the list. If any item is missing, contact Light Machines' Customer Service Department (800/221/2763). Register Your Machining Center You ll find a registration card in the small box with the documentation and software disks. Clearly print all the requested information and return this card to Light Machines Corporation. Unpack the Machining Center 1. Position the pallet near the table on which you ll set the Machining Center. The table should be located against a wall for maximum support. 2. Remove the staples holding the bottom of the cardboard container to the pallet. 3. Lift the cardboard container off of the pallet. 4. Inspect the Machining Center chassis for visible signs of damage such as a broken shield, a dent in the chassis or damaged cables. If any damage is noted, or if you find any discrepancies between the packing slip and the items received, call Light Machines Customer Service Department at (800/221/2763). 5. From underneath the pallet, use a 9/16" wrench to remove the four bolts holding the Machining Center base to the pallet. Keep the bolts and other packaging materials in case you have to return the machine for any reason. Set Up the Machining Center 1. Lift the Machining Center off of the pallet and onto the table. 2. Once on the table, position the Machining Center correctly for machining. 3. Remove the protective paper from the safety shield. Teacher s Guide Installation CNC Technology: 9801 1-3 prolight Mill

Hardware Installation The following paragraphs review the procedures for installing the hardware components of the prolight Machining Center. You should already have your personal computer set up in accordance with the directions in the computer owner s manual. WARNING The first thing you have to do is install the prolight Interface Card in your PC. Do not connect power to the machining center or the computer until instructed to do so in the following procedures. Installing the Interface Card in the PC The Interface Card can be installed in any full-size slot designated for expansion card use. Refer to your computer owner s manual to determine particular expansion card restrictions. Opening the PC Chassis WARNING To install the Interface Card, you must remove the cover of the PC. Refer to the installation instructions supplied with your PC for details on removing the cover. Generally, the cover is secured by four screws through the rear panel; however, some computers may have push latches, or screws in different locations. Disconnect power from your personal computer before opening its chassis cover! Turn off the power switch and remove the power cord to assure that no electrical potential is present when the cover is removed. Do not plug the power cord from the PC chassis into an AC outlet until all installation procedures have been completed and the chassis cover has been closed. Set the cover aside and locate an open slot in which to install the Interface Card. Remove the blank slot cover (if any). Removing the slot cover requires removing a screw at the top rail of the rear panel. You may choose to discard the cover, but save the screw for installing the Interface Card. Unpacking the Interface Card The card is shipped inside an antistatic envelope. Be careful not to create any static discharge when removing the card from the envelope; touch a grounded surface such as the PC chassis, first. Slide the card out of the envelope and inspect it for signs of damage, such as bent or broken components or a warped circuit card. If damage is found, contact Light Machines Corporation immediately Teacher s Guide Installation CNC Technology: 9801 1-4 prolight Mill

Inserting the Interface Card The following procedures describe how to insert and secure the Interface Card in the computer. 1. Grasp the Interface Card at the front and back. 2. Position the card above the bus connector at the chosen slot. The interface connector on the end of the card should face the rear panel of the computer chassis. 3. Slide the card into the bus connector. The interface connector on the card should protrude from the rear panel of the computer. Carefully wiggle the Interface Card back and forth to assure its tightness in the bus connector. Components on the Interface Card should not touch adjacent cards or other components. 4. Secure the Interface Card to the top rail of the rear panel with the screw you saved when removing the blank slot cover. 5. Pay particular attention to the location of the slot in which you inserted the Interface Card. Do not get the Interface Card mixed up with the parallel port which uses the same type of connector. Checking Your Installation After installing the Interface Card, replace the computer chassis cover. Connect the computer power cord and turn the computer on. The computer should perform an internal check, run the operating system and display the windows home screen. If the PC fails to start-up, turn off the power, open the chassis and check your installation to be sure that the Interface Card is located in an appropriate slot and is properly seated. When the Windows home screen appears, choose shut down from the Start menu and install the other hardware components. Connecting the Machining Center WARNING The following paragraphs review the procedures for connecting your computer with the machining center and Controller Box. The Interconnection Diagram has been provided as a visual aid for the recommended connections. Do not connect power to the machining center, the Controller Box or the computer until instructed to do so in the following procedures. Never connect or disconnect the cables with the power on! This will cause damage to the Controller Box drive components. Operate the machining center with all cables firmly secured. Teacher s Guide Installation CNC Technology: 9801 1-5 prolight Mill

Connecting the Machining Center to the Controller Box The interface cables and power cords are long enough to allow the Controller Box to be located up to five feet away from the machining center. Make sure the machining center is placed on a stable, flat surface and leveled properly. The Controller Box can be placed beside the machining center, or mounted on a shelf beneath the machining center. Make sure the power switch on the front of the Controller Box is readily accessible. Keep in mind that you may need to check the fuses on the rear panel of the Controller Box. Locate the Controller Box in an area where it will not be exposed to metal chips or cutting fluid. 1. Route the interface and power cables from the machining center to the Controller Box as shown in the Interconnection diagram. 2. Insert the 15-pin plug from the machining center into the 15-pin receptacle marked A & B AXES on the rear panel of the Controller Box. 3. Insert the 9-pin plug from the machining center into the 9-pin receptacle marked C AXIS on the rear panel of the Controller Box. 4. Insert the AC power plug from the machining center into the 120VAC, threeprong receptacle marked SPINDLE on the rear panel of the Controller Box. 5. Make sure all connectors are secured with screw locks. Connecting the Machining Center to the Computer The spindle cable is attached to the rear panel of the Machining Center and is terminated with a 9-pin plug. Insert this plug into the 9-pin receptacle on the computer Interface Card you installed earlier. Teacher s Guide Installation CNC Technology: 9801 1-6 prolight Mill

prolight 1000 Machining Center Computer with LMC Interface Card installed 9 pin spindle cable 25 pin computer cable Controller Box Machining Center Power Cord 15 pin machine cable 9 pin mill cable 120VAC, 60 Hz AC outlet Spindle power cord Controller Box power cord prolight Machining Center Interconnection Diagram Connecting the Computer to the Controller Box 1. Route the 25-pin cable between the Computer and the Controller Box. 2. Connect the end of the cable marked COMPUTER to the 25-pin connector protruding from the LMC Interface Card in the rear of the computer. Make sure you are plugging the cable into the Interface Card connector, not the parallel port. 3. Connect the other end of the cable to the 25-pin connector marked COMPUTER on the rear panel of the Controller Box. 4. Make sure all connectors are secured. Teacher s Guide Installation CNC Technology: 9801 1-7 prolight Mill

Connecting Power to the Hardware Components Both the machining center and the Controller Box must be plugged into a grounded 120VAC, 60Hz, 15A polarized wall outlet, as shown in the Interconnection Diagram. This outlet must be capable of supplying up to 12 amps of power to the Controller Box. Locate the loose power cord that came with the machining center; this is the power cord for the Controller Box. Insert the receptacle end of this cord into the 120VAC three-prong connector on the back of the Controller Box. Insert the plug end of this cord into a grounded, three-hole, 120VAC, 60Hz wall outlet. Before running the machining center it is important that all safety precautions are followed. If you are not familiar with the machining center, it is recommended that you read through the Users Guide and perform the Tutorial in Section D. We have included a Safety Checklist on the following page to ensure that there is always a copy posted near the machining center. Installing the Control Program (Software) The following instructions assume that your hard drive is drive C, and your floppy drive is drive A. 1. Turn on the computer. Wait for it to go through its internal checks and for it to complete the start up process. 2. When your Windows desktop appears, insert the prolight disk in the computer floppy drive. 3. Using the Windows Explorer, (Start Menu>Programs>Windows Explorer) open the floppy drive. Note: If you are installing on Windows NT, use either the File Manager to access the floppy drive, or select "Run" from the Program Manager. 4. Double click on Setup.exe to start the installation. 5. The Welcome screen appears. You are warned to exit all other running programs. If no other programs are running, click Next. 6. The next screen requests that you enter the destination directory for the Control Program. If you would like to place the Control Program in a directory other than the default directory, click on Browse and select an alternate destination. Otherwise, click Next. 7. A window appears, displaying installation progress, and prompting you on how to proceed. After installation is complete, you are prompted to view the Readme file. It is beneficial to view the Readme file at this time because it contains important information about the software and the machine that may not be included in the User s Guide. 8. Run the Control Program by double clicking the program icon. 9. If running Windows NT, you need to reboot the computer. Teacher s Guide Installation CNC Technology: 9801 1-8 prolight Mill

Uninstalling the Control Program In the event you need to remove the Control Program from your hard drive, there is an uninstall program included on the software disks. The uninstall program was copied onto your hard drive when you installed the Control Program. To uninstall the Control Program, just double click the Remove Program icon (it should be in the same folder as the Control Program). A message appears asking if you are sure you wish to remove the program and all its files. Click on Yes to uninstall, or Cancel to exit the Uninstall program. Teacher s Guide Installation CNC Technology: 9801 1-9 prolight Mill

Safety Checklist Before you enter the work area: q q q Put on safety glasses. Tie back loose hair and clothing. Remove jewelry including rings, bracelets and wristwatches. Before machining a part: q q q q q q q q q q q 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. Only operate the machine after being properly trained in its use. Perform a dry run: q q q Set the spindle speed to lowest manual speed setting. Make certain there is no workpiece in place. Run the NC program to make sure all the moves make sense before running the program with a workpiece in place. After completing the dry run, properly secure the workpiece to the machine. Keep fluids away from all electrical connections, electronic or electrical devices, the computer and nearby electrical outlets. While machining a part: q q q q q q Do not touch moving or rotating parts. Press the Emergency Stop button before 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 workpiece. Pull the Emergency Stop button out only after closing the safety shield. Keep all unauthorized persons away from the work area. Teacher s Guide Installation CNC Technology: 9801 1-10 prolight Mill

Pre-Test 1. On a mill the tool mounts in the? A Spindle B Stepper motor C Cross slide D Workpiece 2. The work piece is? A The same as a workbench B The stock you mill C A tool D None of the above 3. Work Coordinates are A Normally located with the zero point on the top left front corner of the workpiece B Changeable for different workpiece locations C Usually different from machine coordinates D All of the above 4. CNC stands for A Control for New Computers B Computer Numeric Control C Computational Numeric Catalyst D Combined Numeral Components 5. An NC code block is A An unmachined workpiece B A character in an NC program C A line in an NC program D A way to stop a program from running Teacher s Guide Pre-Test CNC Technology: 9801 2-1 prolight Mill

6. End mills and ball mills are A Tools used for cutting B Tools used for grinding C Drill bits D None of the above 7. The axes on a mill are called the A The R, A, T axes B The X, Y, Z axes C The M, N, O axes D The J, K, I axes. 8. You should press the Emergency Stop button on the machining center when A You want to ask the instructor a question B You are changing tools on the machine C After you open the Safety shield D Never 9. Tool path verification is used A Before a part is cut B After a part is cut C To home the machine D To jog the machine 10. An NC file A Is used to fine tune the workpiece B Is never stored on the computer C Can be edited D Is where you keep all of your NC programs 11. You can make adjustments to the machine A When the machine is running B When ever you want C Only when the emergency stop button is pressed in D When the machine is paused during a program Teacher s Guide Pre_Test CNC Technology: 9801 2-2 prolight Mill

12. The spindle axis is A The Y axis B The Z axis C The X axis D The A axis 13. Feed rate is A How fast the machine eats power B How fast the machine turns the spindle C How fast the tool moves into the workpiece D How fast the chips are removed from the workpiece 14. The Jog Control is used to A Home the machine B Jog the cross slide C Raise and lower the spindle D All of the above 15. Machine Home is A Where you store the machine B The point of origin on the workpiece C The top front left corner of the work envelope D The middle of the 3 axes 16. What do you use to hold stock on the cross slide? A A vise B Your hands C Your lab partner D Wire 17. What is the purpose of the safety shield? A Protect the operator from flying chips B Keep foreign objects out of the enclosure C Allow the operator to see the machining process D All of the above Teacher s Guide Pre-Test CNC Technology: 9801 2-3 prolight Mill

18. What is a Dry Run? A Another way to verify your NC program B Running the program with no stock mounted C A way to check that all tool motions make sense D All of the above 19. When you design a part to be machined, what is the first step? A Write the program B Perform a dry run C Sketch the part D Determine stock size 20. Safety is A The least important thing to think about when operating a machine B Something to consider when operating a machine C The most important thing to think about when operating a machine D A position in Football Teacher s Guide Pre_Test CNC Technology: 9801 2-4 prolight Mill

Name: Pre-Test Answer Sheet. 20 uestions. 1 A B C D 2 A B C D 3 A B C D 4 A B C D 5 A B C D 6 A B C D 7 A B C D 8 A B C D 9 A B C D 10 A B C D 11 A B C D 12 A B C D 13 A B C D 14 A B C D 15 A B C D 16 A B C D 17 A B C D 18 A B C D 19 A B C D 20 A B C D Teacher s Guide Pre-Test CNC Technology: 9801 2-5 prolight Mill

Teacher s Guide Pre_Test CNC Technology: 9801 2-6 prolight Mill

Warning! Hazardous Area Manual CNC Activity 2 Worksheet Mill Components Task 2-1 Inventory and Safety Checks o o o o prolight Mill and controller box Computer with WPLM Control Program installed Safety Checklist Lab Station conforms to safety guidelines? Name: What are the 6 things you do not do while machining a part? Why should items like wrenches and keys be removed from the work area before operating the machining center? Task 2-2 Identify Mill components Using your worksheet, fill in the names of the components indicated below. prolight LIGHT MACHINES C O R P O R A T I O N Read User s Guide Follow Safety Precautions Always Wear Safety Glasses Teacher s Guide Worksheets CNC Technology: 9801 3-2 prolight Mill

Name: What is the difference between a mill and a Machining Center? What is the purpose of the Safety Shield, and when is it used? What control on the machining center should you use in an emergency? What part of the machining center rotates the tool? Teacher s Guide Worksheets CNC Technology: 9801 3-3 prolight Mill

Warning! Hazardous Area Read User s Guide Follow Safety Precautions Always Wear Safety Glasses Manual CNC LIGHT MACHINES C O R P O R A T I O N Task 2-3 Axes Identification Name: Using the worksheet, draw and label the 3 axes, and the positive and negative directions on each. prolight What parts of the Machining Center do the X axis, Y axis and Z axis stepper motors move? Task 2-4 Controller components Where is the controller power on/off switch located? Where is the controller fuse panel located? What does the Controller Box do? Teacher s Guide Worksheets CNC Technology: 9801 3-4 prolight Mill

Task 2-6 Discussion and Review What have you learned about Milling? Name: About Safety? List 3 things that you think are important to know when using the Machining Center. Inventory Checklist o prolight Mill is at Home position. o Mill is powered off. o Controller box is powered off. o Computer is off. o All tools and workpieces are returned to the shelf. Teacher s Guide Worksheets CNC Technology: 9801 3-5 prolight Mill

Activity 3 Worksheet Control Program Inventory and Safety Checks o prolight Mill and controller box o Computer with WPLM Control Program installed o Safety Checklist o Lab Station conforms to safety guidelines? Task 3-4 Standard Tool Bar There are 3 ways to save an NC program. List 2 of them. Name: Task 3-6 Inputs Tool Bar What happens different from when you did this exercise with the outputs toolbar? Task 3-8 Status Bar As you move the mouse around the screen, observe the message area on the left side of the bar. Which indicators are on and which are off? Does the clock read the correct time? Task 3-11 Discussion and Review What are some of the advantages of having a computer controll a mill rather than a person? Teacher s Guide Worksheets CNC Technology: 9801 3-6 prolight Mill

Name: Do you think this is better than having a person do the controlling? More economical? Inventory Checklist o prolight Mill is at Home position. o Mill is powered off. o Controller box is powered off. o Computer is off. o All tools and workpieces are returned to the shelf. Teacher s Guide Worksheets CNC Technology: 9801 3-7 prolight Mill

Activity 4 Worksheet Mounting the Stock Inventory and Safety Checks o prolight Mill and controller box o Computer with WPLM Control Program installed o Safety Checklist o Lab Station conforms to safety guidelines? Task 4-5 Setting the Stock Parameters Did the graphic in the Verify window change at all? Name: Task 4-6 Discussion and Review What are 2 types of vises? What basic principles does a mechanical vise use to hold an object in place? What does a pneumatic vise use to secure an object? Inventory Checklist o prolight Mill is at Home position. o Mill is powered off. o Controller box is powered off. o Computer is off. o All tools and workpieces are returned to the shelf. Teacher s Guide Worksheets CNC Technology: 9801 3-8 prolight Mill

Activity 5 Worksheet Tooling Name: Inventory and Safety Checks o prolight Mill and controller box o Computer with WPLM Control Program installed o Safety Checklist o Lab Station conforms to safety guidelines? Task 5-9 uestions What are the two types of automatic tool changing systems? What type of tool would you use to cut a contoured shape from a workpiece? It is perfectly safe to handle cutting tools with your bare hands. True or False You should never leave any tools or other hardware in the enclosure. True or False Task 5-10 Discussion and Review How would it affect the control program if you had not defined the tool, or if you input the wrong information? Inventory Checklist o prolight Mill is at Home position. o Mill is powered off. o Controller box is powered off. o Computer is off. o All tools and workpieces are returned to the shelf. Teacher s Guide Worksheets CNC Technology: 9801 3-9 prolight Mill

Activity 6 Worksheet Home Positions Inventory and Safety Checks o prolight Mill and controller box o Computer with WPLM Control Program installed o Safety Checklist o Lab Station conforms to safety guidelines? Task 6-3 Home the Machine What is Machine Home? Name: Where is Machine Home? Task 6-4 Set Workpiece Origin What is a coordinate? What code can be used to Home the system? What is another name for Work Coordinates? Do you think you could have the workpiece origin somewhere other than the front left corner of the workpiece? Teacher s Guide Worksheets CNC Technology: 9801 3-10 prolight Mill

Task 6-6 Discussion and Review Name: What do you think would happen if you set the workpiece origin first, and then homed the machine, to the wrong position? Inventory Checklist o prolight Mill is at Home position. o Mill is powered off. o Controller box is powered off. o Computer is off. o All tools and workpieces are returned to the shelf. Teacher s Guide Worksheets CNC Technology: 9801 3-11 prolight Mill

Activity 7 Worksheet Selecting an NC Program Inventory and Safety Checks o prolight Mill and controller box o Computer with WPLM Control Program installed o Safety Checklist o Lab Station conforms to safety guidelines? Task 7-3 Selecting an NC Program What is an NC program? Name: What happens to the file in the edit window? The Status Bar? Task 7-5 Adjust the View Why would you want a different view of the part in the verify program? Task 7-6 Adjust the Stock What might happen if you put the wrong sizes in the stock window? Task 7-8 Team Discussion and Review How does the computer file system make it easier to operate the computer? What are some of the things the NC program controls? Teacher s Guide Worksheets CNC Technology: 9801 3-12 prolight Mill

Name: Inventory Checklist o prolight Mill is at Home position. o Mill is powered off. o Controller box is powered off. o Computer is off. o All tools and workpieces are returned to the shelf. Teacher s Guide Worksheets CNC Technology: 9801 3-13 prolight Mill

Activity 8 Worksheet Name: Verify and Dry Run the Program Task Inventory and Safety Checks o prolight Mill and controller box o Computer with WPLM Control Program installed o Safety Checklist o Lab Station conforms to safety guidelines? 8-4 Estimate Run Time What happens? What information does the dialog box give you? How long will the Millone program run? How far will the spindle travel? Why would you want to know how long a program will run? What other reasons are there for knowing the runtime? Task 8-5 Verify Millone.nc If there are any problems, the message bar at the top of the screen will turn red, and a message will appear in the middle of the screen. How does tool path verification check the program for errors? Teacher s Guide Worksheets CNC Technology: 9801 3-14 prolight Mill

Name: Did your program run through verification without any problems? If not, what were the problems? How did you fix them? Task 8-6 Dry Run the NC Program What is a Dry Run? What are the things to look for during a dry run? Did you get any error messages while the program was running? How would you correct them if you did? If you had to edit the program at all, be sure to save your changes before you exit the program. Task 8-7 Team Discussion and Review Why do you think it is so important to verify the nc program in different ways before actually cutting the part? What are some of the dangers of just running the program? Inventory Checklist o prolight Mill is at Home position. o Mill is powered off. o Controller box is powered off. o Computer is off. o All tools and workpieces are returned to the shelf. Teacher s Guide Worksheets CNC Technology: 9801 3-15 prolight Mill

Activity 9 Worksheet Run the NC Program Task Inventory and Safety Checks o o o o prolight Mill and controller box Computer with WPLM Control Program installed Safety Checklist Lab Station conforms to safety guidelines? 9-8 Run the Program Name: Where on the control program screen does it tell you the run time of the NC program? Check your worksheet from Activity 8. How long did it actually take to run the program? Was the Estimate Run Time function correct? Task 9-9 Discussion and Reveiw Did you encounter any problems while running the Millone program? Would you like to learn more about NC programming, so that you could make your own parts? What kind of parts would you like to mill? Teacher s Guide Worksheets CNC Technology: 9801 3-16 prolight Mill

Activity 10 Worksheet NC Programming Task Inventory and Safety Checks o prolight Mill and controller box o Computer with WPLM Control Program installed o Safety Checklist o Lab Station conforms to safety guidelines? 10-1 uestions Briefly answer the following questions. 1. What is a part program? Name: 2. What are the two parts of an NC word? 3. Here are some new terms you learned in this station. Write a brief definition of each term. Code- Address Character- Word- EIA RS-274D Standard Format- Teacher s Guide Worksheets CNC Technology: 9801 3-18 prolight Mill

Name: Parameter- Block- Preparatory Code- 4. Match the NC words in the first column to their correct meaning in the second column. M02 a. Move the tool to 2.5 on the X axis (absolute) G90 T1 J.5 G00 X2.5 N12 G02 F1 Z.25 I.15 M05 b. Move the tool to.25 on the Z axis (absolute) c. Move the tool rapidly to the indicated position d. Make the center point of the arc.15 on the X axis e. Use clockwise circular interpolation f. End of program g. Turn off the spindle motor h. Make the center point of the arc.5 on the Y axis i. Use incremental coordinates j. Use absolute coordinates k. Move the tool at a feed rate of one inch per minute l. This is the block marked number twelve G91 m. Use tool #1 5. Some blocks from an NC program are listed below. Each block contains several words. Write an explanation of each word in the space provided. Teacher s Guide Worksheets CNC Technology: 9801 3-19 prolight Mill

Block Explanation N0G0G90Z.1 N0 - G0 - G90 - Z.1 - N1M3 N1 - M3 - N2G1X2.5Y3F2 N2 - N43G0Z.1 N44M2 G1 - X2.5 - Y3 - F2 - N43 - G0 - Z.1 - N44 - M2 - Name: 6. What is wrong with the following NC blocks? Some of these blocks will actually work, but are not written in the best way according to the programming rules. N1X.5Y.5G90 N29G0X.5Y.5M2M47 N3X.5Y.5F2 N4X.5Y1.5F2 N04X0.50Y0.7500F2.00 Teacher s Guide Worksheets CNC Technology: 9801 3-20 prolight Mill

N5G0X.25X.5Y1 Name: N6G91X2Y3; MOVE TO ABSOLUTE POSITION X=2 Y=3 N12G1X2Y3,RAPID TRAVERSE TO X2,Y3 N2G9OX2Y3;F1 Task 10-2 Discussion and Review If you do not have the control program running on your computer, start it now. Locate and open the Millone program. Does the code in the program make more sense to you than it did before? Can you pick out specific blocks of instruction, such as starting and stopping the spindle? Can you tell what the programmed feed rate was? What else can you see? Inventory Checklist o prolight Mill is at Home position. o Mill is powered off. o Controller box is powered off. o Computer is off. o All tools and workpieces are returned to the shelf. Teacher s Guide Worksheets CNC Technology: 9801 3-21 prolight Mill

Activity 11 Worksheet Coordinate Systems Task Inventory and Safety Checks o prolight Mill and controller box o Computer with WPLM Control Program installed o Safety Checklist o Lab Station conforms to safety guidelines? Task 11-1 Locating Points Use the following graphic to locate the points described below. +Y Name: 5 uadrant II (-x,+y) 4 3 2 uadrant I (+x,+y) 1 -X -5-4 -3-2 -1-1 0,0 1 2 3 4 5 +X -2 uadrant III (-x,-y) -3-4 -5 uadrant IV (+x,-y) w -Y The coordinate X2,Y3 is located in uadrant I. In which quadrant will we find X-2,Y-3? How about X2,Y-3? w w Using inches as the units, measure 2 inches along the X axis from the point of origin. Next, measure 3 inches along the Y axis from the point of origin. We come to an intersection, where X=2 and Y=3. This point can be given the coordinate X2,Y3 (or 2,3). Note: Always give the X value first. Units can also represent fractions of an inch. Measure 3.5 inches along the X axis and 2.5 inches along the Y axis; the coordinate point is X3.5,Y2.5. Any fraction can be used:.75,.625,.125. (In NC programming, fractions are written in decimal form.) Teacher s Guide Worksheets CNC Technology: 9801 3-22 prolight Mill

Task 11-2 uestions What is a coordinate? Name: What is the theory of René Descartes' coordinate system? What is the point where the axes meet called, and what is the value on each axis at this point? Task 11-3 uestions How is a three-dimensional coordinate system different from a two-dimensional coordinate system?. Draw a two-dimensional coordinate system with X and Y axes. a) Show these four points: X-2,Y3; X4,Y5; X5,Y-1; X-1,Y-1 b) In which quadrant is each of these coordinates located? Teacher s Guide Worksheets CNC Technology: 9801 3-23 prolight Mill

Task 11-4 Absolute and Incremental uestions Name: Using absolute programming mode, give the X and Y coordinates (in order from Start Point to End Point) for each point shown in the illustration below. Start Point: Point A: Point B: End Point: Using incremental programming mode, give the X and Y coordinates (in order from Point A to End Point) for each point shown in the illustration below. Point A: Point B: End Point: Y 5 4 3 Point B End Point 2 Point A 1 0,0 Start Point 1 2 3 4 5 X Teacher s Guide Worksheets CNC Technology: 9801 3-24 prolight Mill

Task 11-5 uestions What is interpolation? Name: What kind of motion does linear interpolation use? What two points must be specified for linear motion? What kind of motion does circular interpolation use? What three points must be specified for circular motion? Task 11-6 Discussion and Review Briefly answer the following questions. 1. Using linear interpolation and absolute programming, draw an X,Y coordinate system with a tool path for these coordinates: Start Point: X.5,Y1 Point A: X1.5,Y2 Point B: X2.5,Y2 Point C: X3.5,Y3 End Point: X5,Y3 Make sure to label the X and Y axes, the units and the coordinates. Teacher s Guide Worksheets CNC Technology: 9801 3-25 prolight Mill

Name: 2. Using circular interpolation and absolute programming, draw an X,Y coordinate system and the tool path for these coordinates: Arc 1 Start point: End point: Center Point: Arc 2 Start point: End point: Center Point: X1,Y1 X3,Y3 X3,Y1 X3,Y3 X5,Y5 X3,Y5 Make sure to label the X and Y axes, the units and the coordinates. 3. Does the tool move in a clockwise or counterclockwise direction for arc1?how about arc 2? Inventory Checklist o prolight Mill is at Home position. o Mill is powered off. o Controller box is powered off. o Computer is off. o All tools and workpieces are returned to the shelf. Teacher s Guide Worksheets CNC Technology: 9801 3-26 prolight Mill

Activity 12 Worksheet Name: Developing an NC Program Task Inventory and Safety Checks o prolight Mill and controller box o Computer with WPLM Control Program installed o Safety Checklist o Lab Station conforms to safety guidelines? Task 12-8 Create USA.NC 2.0 1.75 1.55 1.0.45.25 3.0 2.7 2.1.9.6.3 1.2.6.8 1.2 1.4 1.8.2 w Use the graph provided with the worksheets to draw the part shown. You may wish to begin by placing a small dot at the coordinate for each point on the star, and writing in the coordinates. Then draw the cutting lines from dot to dot. When you've finished, do the same for each letter. Teacher s Guide Worksheets CNC Technology: 9801 3-27 prolight Mill

Name: Y 2.3 2.2 2.0 2.1 1.9 1.8 1.7 1.6 1.5 1.4 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 X 1.3 1.2 1.0 1.1 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0 0.1 Teacher s Guide Worksheets CNC Technology: 9801 3-28 prolight Mill

w w Name: When you plan the sequence for each cut, don't forget to include the Z axis moves; when to insert and when to extract the cutter. Your next task is to enter your NC code on an NC coding sheet. Use the two NC coding sheets that are part of the Activity Worksheets. Do not write in this book. When you fill in the NC coding sheet, don't forget to turn the spindle on and off and set the feed rate. Teacher s Guide Worksheets CNC Technology: 9801 3-29 prolight Mill

Name: Teacher s Guide Worksheets CNC Technology: 9801 3-30 prolight Mill

12-8 Team Discussion and Review 1. Put these steps in the correct sequence (1 6). a) Determine stock and tool b) Enter NC code on coding sheet c) Determine feed and depth of cut d) Sketch the part e) Determine cutting sequence f) Draw the part to scale Name: 2. Greater feed rates and depths of cut can be specified when cutting softer materials like: a) Steel b) Machinable wax c) Aluminum 3. If the top of the workpiece is established as Z = zero, then cutting into the workpiece represents a: a) Negative Z value b) Positive Z value c) Either positive or negative Z value 4. Stock size should be: a) As large as possible b) As small as possible c) Any size, as long as it fits in the Machining Center 5. When cutting a flat surface, which type of end mill should be used: a) Any end mill available b) Ball end mill c) Flat, center-cutting end mill Inventory Checklist o o o o o prolight Mill is at Home position. Mill is powered off. Controller box is powered off. Computer is off. All tools and workpieces are returned to the shelf. Teacher s Guide Worksheets CNC Technology: 9801 3-31 prolight Mill

Activity 13 Worksheet Editing Your NC Program Name: Task Inventory and Safety Checks o prolight Mill and controller box o Computer with WPLM Control Program installed o Safety Checklist o Lab Station conforms to safety guidelines? Task 13-6 Discussion and Review 1. What types of problems did you run into writing your NC program? 2. What do you think would be the result of improper coding in an NC program? 3. After editing a part program, the program remains in the computer: a) Forever b) Until the program is deleted c) Until the computer is turned off, unless you save the program 4. List two (2) mistakes that commonly occur when entering a part program. 5. When entering a part program, the address characters must be typed as: a) Upper-case letters b) Lower-case letters c) Upper- and/or lower-case letters Teacher s Guide Worksheets CNC Technology: 9801 3-32 prolight Mill

Name: 6. Before adding a comment to a line of NC Code, type a: a) Space b) Semicolon c) Comma d) None of the above 7. Complete the following sentences. a) An address character together with its parameter is called a. b) A line of NC code is called a. Inventory Checklist o prolight Mill is at Home position. o Mill is powered off. o Controller box is powered off. o Computer is off. o All tools and workpieces are returned to the shelf. Teacher s Guide Worksheets CNC Technology: 9801 3-33 prolight Mill

Activity 14 Worksheet Name: Verify and Run Your Program Task Inventory and Safety Checks o prolight Mill and controller box o Computer with WPLM Control Program installed o Safety Checklist o Lab Station conforms to safety guidelines? 14-6 Verify the Program Did your program run through verification without any problems? If not, what were the problems? How did you fix them? Task 14-7 Dry Run the NC Program Do you get any error messages while the program is running? How would you correct them if you did? Task 14-11 Discussion and Review Why do you think it is so important to verify the nc program in different ways before actually cutting the part? What are some of the dangers of just running the program? Teacher s Guide Worksheets CNC Technology: 9801 3-34 prolight Mill

Activity 15 Worksheet Conclusion Name: Final Projects Task 15-1 Final Project Choose one of the following projects: 1. House: The house is 1.5" tall and 1.5" wide, with a.25" high roof on it. It should be centered on the workpiece. Use a 1/8" end mill, and a 3"x2"x1.5" block of machinable wax for a workpiece. The cut depth should be less than.25". Teacher s Guide Worksheets CNC Technology: 9801 3-36 prolight Mill

Name: 2. Three Blocks: The two end blocks are 1" square, and the middle block is.75". Again use a.125 inch end mill and the 3"x2"x1.5" block of machinable wax for a workpiece. The cut depth should be less than.25". Start the lower left corner of the first block at 0.25, 0.25 ; the middle block bottom corner at 1.5, 0.5 ; and the third block bottom left corner at 1.75, 0.75. Create a part drawing, and an NC program to machine your part. Use the graph paper and coding sheets provided in the activity worksheets. Don't forget to include tooling specifications, stock size and stock type. If time permits, you may be able to verify and run your program on the Machining Center. Good luck. Teacher s Guide Worksheets CNC Technology: 9801 3-37 prolight Mill