CNC Mill Training System (Light Duty)

CNC Mill Training System (Light Duty) LabVolt Series Datasheet Festo Didactic en 120 V - 60 Hz 07/2018

Table of Contents General Description 2 Features & Benefits 2 List of Equipment 3 List of Manuals 3 Table of Contents of the Manual(s) 3 Additional Equipment Required to Perform the Exercises 3 Optional Equipment 3 System 4 Equipment Description 4 Optional Equipment Description 9 General Description The CNC Mill Training System provides training in computer-aided manufacturing (CAM) using a microprocessor-driven, light-duty CNC mill. The system allows students to practice computer numerical controlled (CNC) code programming and editing, learn to operate mill components, controls, and tools, set a programmed reference zero, follow the steps necessary to machine a part to programmed specifications, and apply the machine code language to current mill technology. A computer is used to create NC part programs with the G and M machine codes or their conversational code equivalents. The created programs are downloaded to the on-board microprocessor of the CNC mill, which stores and executes them. Since the CNC mill connects directly to the serial or Ethernet port of a computer, or directly to a network, no additional interface card is required. The computer is free to be used for any additional applications, since it is not dedicated to the control of the mill. The CNC Mill Training System comprises the accessories, software, and cables required for system operation. These include a vise, a basic milling set, 100 blocks of industrial machinable wax, a serial cable, a cross-over Ethernet cable, and the CNC Mill Software, Model 5660. The training system also includes two user guides. The first user guide allows students to acquire experience with the equipment commonly found in automated manufacturing environments. The second user guide covers the operation of the CNC Mill Software. Various assortments of milling tools and stock materials of different sizes are offered as options to enhance and expand system capabilities. Features & Benefits Key-released emergency stop push button Ability to restart programs from stopping point after safety interruption On-board embedded microprocessor Computer free to be used for other applications since it is not dedicated to the control of the mill Stand-alone manual mode operation Batch mode for independent operation or operation in CIM Cells Software included with full 3D tool path emulator and easy-to-use graphical interface allowing the programming of up to twenty tools 12-key membrane keypad with 20-character by 4-line LCD display Feed-rate and spindle-speed override capability Removable side panel for access to robot 2 Festo Didactic

Connects to host computer through RS-232 or Ethernet port List of Equipment Qty Description Model number 1 CNC Mill (Light Duty) 5400-B0 1 Wax Milling Stock Set 5404-00 1 Fabricus Software (Domestic Market) - 1 User 5460-00 1 CNC Mill Software - 1 User 5660-00 List of Manuals Manual Description number CNC Mill Software (User Guide) 36189-E0 Fabricus (Quick Start Guide) 37863-E0 CNC Mill (Light Duty) (User Guide) 39547-E0 Table of Contents of the Manual(s) CNC Mill Software (User Guide) (36189-E0) 0 Installation of the CNC Lathe/Mill Software 1 Overview of the CNC Mill Software 2 Menus 3 The Part Program Editors 4 Tutorial Exercises Fabricus (Quick Start Guide) (37863-E0) 0 Introduction 1 Installation 2 Using Fabricus Software 3 Creating Parts CNC Mill (Light Duty) (User Guide) (39547-E0) 1 Overview and Installation 2 Tools and Accessories 3 Using the Mill Interface 4 Milling Stock 5 Tutorial Exercise 6 Maintenance Additional Equipment Required to Perform the Exercises Model Qty Description number 1 1 Personal Computer 8990-00 Optional Equipment 1 Refer to the Computer Requirements in the software section of this datasheet if the computer is to be provided by the end-user. Festo Didactic 3

Qty Description Model number 1 Wax Milling Stock Set 5403-00 1 Wax Milling Stock Set 5404-00 1 Plexiglass Milling Stock Set 5405-00 1 Plexiglass Milling Stock Set 5406-00 1 Engraving Plate Set 5407-00 1 Plexiglass Milling Stock Set 5408-00 1 Aluminum Milling Stock Set 5409-00 1 End Mill Set 5413-00 1 Intermediate Milling Set 5414-00 1 Engraver Tool Set (Project Lead the Way) 5419-00 1 2 Pneumatic Vise 5434-00 1 Plexiglass Milling Stock Set 5441-00 1 Mill Tool Set 32933-00 1 Hold-Down Set 95331-00 1 Mill Vise 97062-00 System Power Requirements Current Service Installation Physical Characteristics Intended Location (H x W x D) Net Weight 2 A Standard single-phase ac outlet On a table able to support the weight of the equipment 750 x 864 x 597 mm (29.5 x 34 x 23.5 in) 70.3 kg (155 lb) Equipment Description CNC Mill (Light Duty) 5400-B0 The CNC Mill can machine pieces of soft materials such as wax and plexiglass, as well as harder materials such as aluminum and brass. It consists of a milling table, a headstock carrying the spindle motor, and a vertical column with dovetail slide. The stock can either be mounted directly on the mill table or secured in a vise that holds it to the table. Two lead screws, each driven by a stepper motor, are used to move the table along the X axis (left and right) and Y axis (backward and forward) to feed the stock through the periphery of the end mill. A third lead screw, also driven by a stepper motor, is used to move the headstock along the Z axis (up and down) for positioning the end mill. The speed of each stepper motor can be programmed separately for feed rates of up to 356 mm/min (14 in/min). A 60 W (0.08 hp) motor rotates the spindle at speeds 2 Requires compressed air 4 Festo Didactic

programmable up to 2800 r/min. The end mill can be changed to accommodate different stock materials and milling designs. The CNC Mill features a control panel that allows manual operation. This panel includes a multiple-line LCD display, an easy-to-use membrane keypad, an error indicator/pause button, and a key-released emergency stop push button. The mill parameters, including the spindle speed, the feed rate, the reference point, and the X, Y, and Z axes coordinates can be set by accessing different menus. During the machining, the control panel displays the X, Y, and Z axes coordinates, as well as the current feed and spindle speed. The CNC Mill is designed for maximum safety. A safety door provides protection during machining. Magnetic interlocks located on this door stop the spindle and the axes if the door is opened during machining. Limit switches prevent over-travel of the spindle and table of the mill. Pressing the emergency stop push button on the control panel powers off the spindle motor and stops the axes. The CNC Mill supports low-voltage communications with robotic units to allow students to create automated work cells, ideal for implementing computer-integrated manufacturing (CIM). For this purpose, the CNC Mill features a 15-pin TTL/IO port providing four 5 V digital inputs and four 5 V digital outputs for TTL communication to an automation work cell. This port can be connected, for example, to the Servo-Robot, Model 5250, offered as an option to achieve automatic loading and unloading of the stock with a robot arm. The CNC Mill also features a 5-pin solenoid driver port providing connections for up to four auxiliary devices. This port can be connected, for example, to the pneumatic control box of the optional Pneumatic Vise, Model 5434, to achieve automatic clamping and unclamping of the stock loaded in the CNC Mill. The TTL/IO and solenoid driver ports of the CNC Mill are M-code supported through the CNC Mill Software, Model 5660. Manual Manual Description number CNC Mill (Light Duty) (User Guide) 39547-E0 Table of Contents of the Manual(s) CNC Mill (Light Duty) (User Guide) (39547-E0) 1 Overview and Installation 2 Tools and Accessories 3 Using the Mill Interface 4 Milling Stock 5 Tutorial Exercise 6 Maintenance Power Requirements Current Service Installation Mechanical Working Range X Axis (Longitudinally) Y (Transversely) Z Axis (Vertically) Positioning Repeatability Resolution Milling Table Surface 2 A Standard single-phase ac outlet 184 mm (7.25 in) 102 mm (4 in) 159 mm (6.25 in) ±0.025 mm (±0.001in) ±0.00318 mm (±0.000125 in) 69.9 x 330 mm (2.75 x 13 in) Festo Didactic 5

Hold-Down T Slots 6.35 mm (0.25 in) width, 38 mm (1.5-in) spacing Maximal Table-to-Spindle Clearance 203 mm (8 in) Cutting Spindle Throat Clearance 88.9 mm (3.5 in) Spindle Taper No. 1 Morse Spindle Nose Thread 0.75 in major diameter, 16 threads/in Main Spindle Drive Continuous Speed Range 0-2800 r/min Motor 60 W (0.08 hp) Feed Motors Type Stepper Resolution 400 steps/rev Rapid Traverse Speed 356 mm/min (14 in/min) Square Wood Shims 47.63 x 47.63 x 9.53 mm (1.875 x 1.875 x 0.375 in) Rectangular Wood Shim 152.4 x 76.2 x 9.53 mm (6 x 3 x 0.375 in) Plexiglass Block 127 x 63.5 x 9.53 mm (5 x 2.5 x 0.5 in) Engraving Plate Holder Maximal Holding 203.2 x 50.8 x 3.18 mm (8 X 2 X 0.125 in) Small Mill Vise Jaw Width 50.8 mm (2 in) Opening Between Jaws 50.8 mm (2 in) Accessories Two clamps with screws and T-nuts to attach to the mill table Large Mill Vise Jaw Width 70 mm (2.76 in) Opening Between Jaws 152.4 mm (6 in) Accessories four screws with T-nuts to attach to the mill table Dial Indicator Set Range 0-25.4 mm (0-1 in) Graduation 0.0254 mm (0.001 in) Accessories Lever-released magnetic base and adjustable clamps Null Modem Serial Cable Length 3.05 m (10 ft) Connectors DB9 female/female TTL/IO Cable Length 3.05 m (10 ft) Connectors DB15 male/male Ethernet Crossover Cable Length 2.13 m (7 ft) Connectors RJ45 male/male End Mills with Two Flutes Types: Square nose, 1 end, shank diameter of 9.525 mm (3/8 in), mill diameter of 3.175 mm (1/8 in) Square nose, 1 end, shank diameter of 9.525 mm (3/8 in), mill diameter of 6.35 mm (1/4 in) Square nose, 2 ends, shank diameter of 4.763 mm (3/16 in), mill diameter of 1.588 mm (1/16 in) End Mills with Three Flutes Types: Ball nose, 1 end, shank diameter of 6.35 mm (1/4 in), mill diameter of 3.175 mm (1/8 in) Square nose, 1 end, shank diameter of 6.35 mm (1/4 in), mill diameter of 3.175 mm (1/8 in) Hold Down Set Two strap clamps with bolts, T-nuts, washers, and various lengths of socket head cap screws End Mill Holders See Model 32933 Edge Finder See Model 32933 Tool Set Hex keys, wrench, and cleaning brush Physical Characteristics Intended Location On a table able to support the weight of the equipment (H x W x D) 750 x 864 x 597 mm (29.5 x 34 x 23.5 in) Net Weight 70.3 kg (155 lb) 6 Festo Didactic

Wax Milling Stock Set 5404-00 The Wax Milling Stock Set includes 100 wax milling stocks. Each stock has the following dimensions: 50.8 x 50.8 x 12.7 mm (2 x 2 x 0.5 in). Additional sets can be ordered separately. Quantity Wax Milling Stocks 100 50.8 x 50.8 x 12.7 mm (2 x 2 x 0.5 in) Fabricus Software (Domestic Market) - 1 User 5460-00 separately. The Fabricus Software is an entry level CAD/CAM software used to easily create G and M machine code files. These files can then be loaded to the appropriate location for compilation, emulation and cutting using the CNC Mill Software and CNC mill. The Fabricus Software is required to perform the exercises in the Tech- Design curriculum. Additional licenses can be ordered Manual Description Manual number Fabricus (Quick Start Guide) 37863-E0 Table of Contents of the Manual(s) Fabricus (Quick Start Guide) (37863-E0) 0 Introduction 1 Installation 2 Using Fabricus Software Festo Didactic 7

3 Creating Parts Features & Benefits Direct interface to CNC Mill Software Shows tool path and PRZ position Draw, move, rotate, and size shapes using either the mouse or a dialog box for further precision Text engraving Draws pockets, grooves, ellipse cups, and islands Outputs G and M code files Program feed, speed, and depth of pass Validation of tool paths given a tool diameter Tool library Licenses Number of Users 1, 5, 10, 15, 20 or 25 Computer Requirements A currently available personal computer with USB 2.0 ports, running under one of the following operating systems: Windows 7 or Windows 8. CNC Mill Software - 1 User 5660-00 Additional licenses are available. The CNC Mill Software is a 32-bit software that runs under Windows. It features a parametric-based graphical tool editor, a 3D tool path emulator, and an easy-to-use graphical interface. The software can import NC part programs created with other CAM programs that support the G and M codes. Manual Manual Description number CNC Mill Software (User Guide) 36189-E0 Table of Contents of the Manual(s) CNC Mill Software (User Guide) (36189-E0) 0 Installation of the CNC Lathe/Mill Software 1 Overview of the CNC Mill Software 2 Menus 3 The Part Program Editors 4 Tutorial Exercises 8 Festo Didactic

Licenses Number of Users 1, 5, 10, 15, 20, 25, 30, or 35 Computer Requirements Optional Equipment Description Wax Milling Stock Set (Optional) 5403-00 A currently available personal computer with USB 2.0 ports, running under one of the following operating systems: Windows 7 or Windows 8. The Wax Milling Stock Set includes 100 wax milling stocks. Each stock has the following dimensions: 127 x 63.5 x 12.7 mm (5 x 2.5 x 0.5 in). Quantity Wax Milling Stocks 100 127 x 63.5 x 12.7 mm (5 x 2.5 x 0.5 in) Plexiglass Milling Stock Set (Optional) 5405-00 The Plexiglass Milling Stock Set includes plexiglass milling stocks that have the following dimensions: 15 smaller rectangular milling stocks: 127 x 63.5 x 12.7 mm (5 x 2.5 x 0.5 in) 10 larger rectangular milling stocks: 152.4 x 76.2 x 12.7 mm (6 x 3 x 0.5 in) 15 square milling stocks: 50.8 x 50.8 x 12.7 mm (2 x 2 x 0.5 in) Smaller Rectangular Milling Stocks Quantity 15 Larger Rectangular Milling Stocks Quantity 10 Square Milling Stocks Quantity 15 127 x 63.5 x 12.7 mm (5 x 2.5 x 0.5 in) 152.4 x 76.2 x 12.7 mm (6 x 3 x 0.5 in) 50.8 x 50.8 x 12.7 mm (2 x 2 x 0.5 in) Plexiglass Milling Stock Set (Optional) 5406-00 The Plexiglass Milling Stock Set includes 100 plexiglass milling stocks. Each stock has the following dimensions: 127 x 63.5 x 12.7 mm (5 x 2.5 x 0.5 in). Quantity Plexiglass Milling Stocks 100 127 x 63.5 x 12.7 mm (5 x 2.5 x 0.5 in) Festo Didactic 9

Engraving Plate Set (Optional) 5407-00 The Engraving Plate Set includes 50 engraving plates. Each plate has the following dimensions: 203.2 x 50.8 x 3.18 mm (8 x 2 x 0.125 in). Quantity Engraving Plates 50 203.2 x 50.8 x 3.18 mm (8 x 2 x 0.125 in) Plexiglass Milling Stock Set (Optional) 5408-00 The Plexiglass Milling Stock Set includes 25 plexiglass milling stocks. Each stock has the following dimensions: 152.4 x 76.2 x 12.7 mm (6 x 3 x 0.5 in). Quantity Plexiglass Milling Stocks 25 152.4 x 76.2 x 12.7 mm (6 x 3 x 0.5 in) Aluminum Milling Stock Set (Optional) 5409-00 The Aluminum Milling Stock Set includes 50 aluminium milling stocks. Each stock has the following dimensions: 50.8 x 50.8 x 12.7 mm (2 x 2 x 0.5 in). Quantity Aluminum Milling Stocks 50 50.8 x 50.8 x 12.7 mm (2 x 2 x 0.5 in) 10 Festo Didactic

End Mill Set (Optional) 5413-00 The End Mill Set includes the following: One 3.175 mm (1/8 in) end mill with a shank diameter of 9.525 mm (3/8 in), 2 flutes, square end One 6.35 mm (1/4 in) end mill with a shank diameter of 9.525 mm (3/8 in), 2 flutes, square end One 3.175 mm (1/8 in) end mill with a shank diameter of 9.525 mm (3/8 in), 2 flutes, 1 ball end One end mill holder for end mills with a shank diameter of 9.53 mm (3/8 in) Square-End Mill (Smaller) Quantity 1 Shank Diameter 9.525 mm (3/8 in) Mill Diameter 3.175 (1/8 in) End 1, square-shaped Flutes 2 Square-End Mill (Larger) Quantity 1 Shank Diameter 9.525 mm (3/8 in) Mill Diameter 6.35 mm (1/4 in) End 1, square-shaped Flutes 2 Ball-End Mill Quantity 1 Shank Diameter 9.525 mm (3/8 in) Mill Diameter 3.175 (1/8 in) End 1, ball-shaped Flutes 2 End Mill Holder Holds end mills with a shank diameter of 9.53 mm (3/8 in) Intermediate Milling Set (Optional) 5414-00 The Intermediate Milling Set includes the following: One 3.175 mm (1/8 in) end mill with a shank diameter of 9.525 mm (3/8 in), 2 flutes, square end One 4.763 mm (3/16 in) end mill with a shank diameter of 9.525 mm (3/8 in), 2 flutes, square end One 6.35 mm (1/4 in) end mill, with a shank diameter of 9.525 mm (3/8 in), 2 flutes, 1 square end One 1.588 mm (1/16 in) end mill, with a shank diameter of 4.763 mm (3/16 in), 2 flutes, 2 square ends One 3.175 mm (1/8 in) end mill, with a shank diameter of 9.525 mm (3/8 in), 2 flutes, 1 ball end End mill holders for end mills with shank diameters of 4.76 mm (3/16 in) and 9.525 mm (3/8 in) One hold-down set One three-jaw Jacobs chuck Square-End Mill (Smaller) Festo Didactic 11

Quantity 1 Shank Diameter 4.763 mm (3/16 in) Mill Diameter 1.588 mm (1/16 in) Flutes 2 Ends 2, square-shaped Square-End Mills (Larger) Quantity 3 Shank Diameter 9.525 mm (3/8 in) Mill Diameter 3.175, 4.763, and 6.35 mm (1/8, 3/16, and 1/4 in) Flutes 2 End 1, square-shaped Ball-End Mill Quantity 1 Shank Diameter 9.525 mm (3/8 in) Mill Diameter 3.175 mm (1/8 in) Flutes 2 End 1 End Mill Holders Holds end mills with shank diameters of 4.76 mm (3/16 in) and 9.525 mm (3/8 in) Hold-Down Set Refer to Model 95331 for specifications Drill Chuck Type Three-jaw Jacobs chuck Accessories No. 1 Morse arbor and a drawbolt to hold it in place Engraver Tool Set (Project Lead the Way) (Optional) 5419-00 The Engraver Tool Set (Project Lead the Way) includes the following: A collet for end mills with a shank diameter of 4.763 mm (3/16 in) A No. 1 Morse taper One 1.588 mm (1/16 in) end mill with a shank diameter of 4.763 mm (3/16 in), 2 flutes, 2 square ends One 0.794 mm (1/32 in) end mill with a shank diameter of 4.763 mm (3/16 in), 2 flutes, 2 square ends Collet Taper End Mills Quantity 2 Shank Diameter Mill Diameter Ends Flutes 2 For end mills with a shank diameter of 4.763 mm (3/16 in) No. 1 Morse 4.763 mm (3/16 in) 1.588 mm (1/16 in) and 0.794 mm (1/32 in) 2, square-shaped Pneumatic Vise (Optional) 5434-00 The Pneumatic Vise consists of a cylinder-operated, heavy-duty vise used to achieve automatic clamping and unclamping of the stock loaded in the CNC Mill. The Pneumatic Vise is supplied with a pneumatic control box that connects to the solenoid driver port of the CNC Mill, permitting M- 12 Festo Didactic

code control of the extension and retraction of the vise cylinder with the CNC Mill Software, Model 5660. The Pneumatic Vise requires compressed air for operation. Vise Jaws Operation Width Depth Use Vise Cylinder Type Bore Stroke Pneumatic Control Box Maximal Air Supply Vise Control Input Pneumatic Output Ports Pneumatic 63 mm (2.48 in) 9 mm (0.35 in) For 50.8 mm (2 in) square parts Double-acting 22.2 mm (0.875 in) 25.4 mm (1 in) 275 kpa (40 psig) Connects to the solenoid driver port of the CNC Mill 2, the air flow through each port can be metered manually Plexiglass Milling Stock Set (Optional) 5441-00 The Plexiglass Milling Stock Set includes 100 plexiglass milling stocks. Each stock has the following dimensions: 50.8 mm (2 in) x 50.8 mm (2 in) x 12.7 mm (0.5 in). Quantity Plexiglass Milling Stocks 100 50.8 x 50.8 x 12.7 mm (2 x 2 x 0.5 in) Festo Didactic 13

Personal Computer (Optional) 8990-00 The Personal Computer consists of a desktop computer running under Windows 10. A monitor, keyboard, and mouse are included. Power Requirements Current Service Installation 2 A Standard single-phase ac outlet Mill Tool Set (Optional) 32933-00 The Mill Tool Set contains three end mills of various types, a mill holder, and an edge finder. End Mills with Two Flutes Types: End Mill Holders Edge Finder Square nose, 2 ends, shank diameter of 4.763 mm (3/16 in), mill diameter of 1.588 mm (1/16 in) Square nose, 1 end, shank diameter of 9.525 mm (3/8 in), mill diameter of 6.35 mm (1/4 in) Square nose, 1 end, shank diameter of 9.525 mm (3/8 in), mill diameter of 3.175 mm (1/8 in) For 4.763 mm (3/16 in), 6.35 mm (1/4 in), and 9.525 mm (3/8 in) shank diameter end mills Single 9.525 mm (3/8 in) shank, 5.08 mm diameter (0.2 in) head Hold-Down Set (Optional) 95331-00 The Hold-Down Set contains two strap clamps with bolts, T-nuts, washers, and various lengths of socket head cap screws. Accessories Includes: Two strap clamps with bolts T-nuts Washers Various lengths of socket head cap screws 14 Festo Didactic

Mill Vise (Optional) 97062-00 The Mill Vise is ideal for operation with the CNC Mill. Its jaws are 50.8 mm (2 in) wide by 25.4 mm (1 in) deep and open a full 50.8 mm (2 in). The fixed jaw has both a horizontal and vertical "V" groove to better hold round bar stock. The vise includes two clamps for attachment to the CNC Mill. Jaw Width Opening Between Jaws Accessories 50.8 mm (2 in) 50.8 mm (2 in) Two clamps with screws and T-nuts to attach to the mill table Festo Didactic 15

Reflecting the commitment of Festo Didactic to high quality standards in product, design, development, production, installation, and service, our manufacturing and distribution facility has received the ISO 9001 certification. Festo Didactic reserves the right to make product improvements at any time and without notice and is not responsible for typographical errors. Festo Didactic recognizes all product names used herein as trademarks or registered trademarks of their respective holders. Festo Didactic Inc. 2018. All rights reserved. Festo Didactic SE Rechbergstrasse 3 73770 Denkendorf Germany P. +49(0)711/3467-0 F. +49(0)711/347-54-88500 Festo Didactic Inc. 607 Industrial Way West Eatontown, NJ 07724 United States P. +1-732-938-2000 F. +1-732-774-8573 Festo Didactic Ltée/Ltd 675 rue du Carbone Québec QC G2N 2K7 Canada P. +1-418-849-1000 F. +1-418-849-1666 www.labvolt.com www.festo-didactic.com 16 Festo Didactic