Total Commitment to Education and Training WorldWide. Microrouter CNC Machine User's Manual. approved Denford Limited reserves the right to alter any specifications and documentation without prior notice. No part of this manual or its accompanying documents may be reproduced or transmitted in any form or by any means, electronic or mechanical, for any purpose, without the express written permission of Denford Limited.
Contact Information Address: Telephone: Fax: e-mail: Denford Limited, Birds Royd, Brighouse, West Yorkshire, HD6 1NB, UK. General Enquiries +44 (0) 1484 712264 Customer Services +44 (0) 1484 722733 Sales Enquiries +44 (0) 1484 717282 +44 (0) 1484 722160 for sales enquiries contact, sales@denford.co.uk for machine servicing enquiries contact, service@denford.co.uk for customer services and technical support contact, customerservices@denford.co.
Table of Contents Contents Preface Contact Information ....................................................................... 2 Warning Notices ............................................................................ 5 About this Manual .......................................................................... 6 Section 1: Introduction Introducing your Microrouter CNC machine .................................. 7 What is CNC? .............................................................................
Contents Section 6: Work Holding The Work Holding Clamp Rail Components .................................. 40 Assembling the Work Holding Clamp Rails ................................... 41 Using the Work Holding Clamp Rails ............................................. 43 The Vacuum Table Components ................................................... 44 Preparing the Microrouter Working Area ....................................... 45 Fitting and Using the Vacuum Table .......................................
Warning Notices Warranty Disclaimer. The Warranty on your Microrouter CNC machine will be invalidated if any modifications, additional ancillary equipment is fitted, or any adjustments made to the controlling devices without prior notification from Denford Limited. Please refer to the information held in your separate Warranty pack, for specific details. Do not carry out any portable appliance testing (PAT) on any of the supplied equipment. Maintenance Disclaimer.
About this Manual Using this manual Disclaimer Language Contact 6 - Contents This manual provides information describing how to transport, site, setup, operate and maintain the features of your Denford Microrouter CNC machine. This manual does not provide any information regarding the software packages used to control your Denford Microrouter CNC machine - please refer to your separate CNC machine control software manual.
1: Introducing your Microrouter CNC machine Congratulations on your purchase of a Microrouter series CNC machine. In this manual you will learn how to setup and use your Microrouter. The Microrouter is a compact three axes CNC machine, suitable for all levels of Education, Training and Prototyping. It has been designed with you in mind - making the processes involved both safe and easy to use. Main Features: • Designed specifically for Education, Training and Prototyping.
1: What is CNC? CNC (Computer Numerical Control) is the general term used for a system which controls the functions of a machine using coded instructions, processed by a computer. CNC machines are a very important part of the modern manufacturing process. Indeed, many of the different types of products you use everyday have been made using some sort of CNC machine. The CNC Manufacturing Process - Example. The sequence shown below defines the main steps involved in producing a component using a CNC system.
1: Before Beginning to Setup... Before beginning to setup your Microrouter CNC machine, please check your separate order documentation, making sure that all items have been delivered to your establishment. Any missing or damaged items should be reported to Denford Customer Services as soon as possible. Note - x The standard equipment listed here is correct at the time of printing - April, 2002 but is liable to change through continuous development of our products.
2: Safety Features Overview and Precautions Safety Features Overview. The following safety features are standard on your Microrouter CNC machine: • Emergency stop button. • Manually operated, totally enclosed guard door with interlock switch. • Option on control software to check CNC programs using toolpath graphics, prior to machining. • Automatic tool retraction & spindle stop for tool changing. Safety Precautions.
2: Safety Features - Emergency Stop Button The emergency stop button is located on the right front panel of the machine. To active an emergency stop, press the button fully in until it clicks. A circular, red emergency stop button is located on the right front panel of the machine. When pressed, it has the effect of stopping all axes and spindle movements immediately. The interlock switch will also close.
2: Safety Features - Interlock Guard Switch Interlock guard switch mounted behind cabinet metalwork in this area. An interlock guard switch is fitted to the front machine door. The switch itself is hidden from view behind the cabinet metalwork. A closed machine door will remain locked when: • The machine is switched off (ie, not in use). To release the lock, power up the machine, using the square red on/off button on the right cabinet end panel. • The emergency stop button is fully pressed in.
2: Safety Features - Interlock Guard Switch An override facility is provided on the interlock guard switch, allowing temporary removal of the guard lock feature. 1) Using a flat blade, lift and remove the circular black plastic blanking plug. 2) Using a small flat or crosshead screwdriver, loosen the manual override locking screw until the circular black plastic lock screw can be turned.
3: Unpacking & Lifting your Microrouter Cut the top of the delivery box open and carefully remove any packaging, strengtheners and bracing struts, where fitted. To obtain better access to the Microrouter, remove all the sides from the delivery box, leaving the machine standing on its wooden delivery pallet. Remove any support packaging, used to help secure the Microrouter to its pallet. When fitted, these supporting struts are usually positioned between the machine feet sections.
3: Deciding on a Site for your Microrouter Site your Microrouter in a well ventilated room. The Microrouter is a bench mounted machine, so it should be sited on a bench of sturdy construction to take the weight of the machine and of a height which enables comfortable operating and programming to take place.
3: Levelling your Microrouter Your Microrouter rests level on the two hollow sections which run beneath the machine cabinet. The machine itself has been levelled to the machine cabinet prior to dispatch, so it is only necessary to level the table on which the Microrouter is to be situated. 3: Connecting the Mains Supply Warning - x Do not connect cables between any electrical hardware with the mains power switched on, since this could seriously damage components inside your CNC machine.
3: Electrical Diagrams The Electrical Diagrams for your Microrouter are not included in this manual - they are delivered separately in the standard equipment box supplied with your machine. 3: Connecting your PC to the Microrouter Warning - x Do not connect cables between any electrical hardware with the mains power switched on, since this could seriously damage components inside your CNC machine. Your Microrouter CNC machine is controlled using a standard IBM compatible PC (personal computer).
3: Connecting your PC to the Microrouter To connect your PC to the Microrouter: 1) Connect the elements of your PC together as described in your original PC manufacturers operating manual. At this stage, your PC should not be switched on. 2) The PC must be physically connected to the Microrouter, using the supplied RS232 cable. This is the long, thin serial link cable fitted with a 25 pin D male connector at one end and a 9 pin D female connector at the opposite end, as shown below right.
3: Connecting your PC to the Microrouter 4) Connect the remaining 9 pin D female end of the RS 232 cable to the 9 pin D male COM port on your PC, ideally COM 2. Most computers usually have two COM ports situated on the back panel of your PC. If you cannot identify any of the ports on your PC, please refer to your original PC manufacturers operating manual for further guidance.
3: Removal of Protective Coatings Safety First! - x Warning. The silicone lubricant aerosol is extremely flammable. Never use the silicone lubricant aerosol near a naked flame, on any other machine, or for any other purpose. Carefully read and follow any instructions or notices included with the aerosol. Wear safety glasses and a suitable respiratory mask when using the aerosol.
3: Dust Extraction & General Wood Precautions Dust Extraction Exit Hole Location. Connect the hose from your dust extraction system to the exit hole (using an appropriate adaptor if required). General Wood Dust Safety Precautions. Obtain "material safety data sheets" from your material suppliers and enforce the recommended precautions. Be aware that certain hardwood dust particles, such as oak, are known carcinogens. Please consult your materials supplier for further details.
3: Component Connection Schematic Diagram Ancillary Equipment, such as printers or scanners, may also be connected to the Parallel port on the PC. Personal Computer (PC). Desktop Tutor (when available) connects to the PC port labelled COM 1. D Pin *. 25 able 9 to rial C Se rt. Po M1 ort. CO o 2P T OM C To in D *. 5 P ble o 2 al Ca t 9 ri Se i cur Se t. Por llel ara P To le. ong ty D To the Port labelled RS 232. Denford Microrouter CNC Machine. * Note Note Mains Power Supply Plug.
4: Using your Microrouter - Overview Several steps must be completed before the final manufacture of a part. The flowchart below lists the general steps that should be followed for CNC file creation, simulation and final part manufacture, in the recommended order. However, miscellaneous factors may warrant the user to complete the steps in a different order to that shown.
4: General Layout of Microrouter Components Note: Machine Controller PC not shown in photograph. Feed Spindle Override. Override. Enclosed Safety Guard Door. Table Vacuum Pump Switch. Front Cabinet Layout. Safety Guard Door Handle. Fan. Machine ID Panel. EEC Interlock Guard Switch (hidden by cabinet metalwork). Emergency Stop Button. Exit Hole for Dust Extraction System. Removeable Cover Plate (to access X and Y axis components). Lefthand and Rear Cabinet Layout.
4: General Layout of Microrouter Components Righthand Cabinet Layout. Removeable Cover Plate ( to access machine Electrical Panel). RS232 Machine Connection Socket. On/off Power Switch. Mains Power Cable Connection. Panel Filter. Table Vacuum Exhaust Vent. Laminate trimmer plug. Z axis motor. Laminate trimmer. Dust extraction pipe. X axis leadscrew. Z axis leadscrew. Z axis slides. Inside the Microrouter Cabinet (working area). Y axis slides. X axis slide (behind extrusion). Guard brushes.
4: Microrouter - Axis Definitions Z+ Z axis Y+ Machine Back ZY axis Y- X+ X axis X- Machine Front X Axis. The X axis slides run at 90 degrees to the Y and Z axes, horizontally left and right, when viewed from the front of the machine. Minus (-) X movements run towards the left end of the machine and positive (+) X movements run towards the right end of the machine. Y Axis.
4: Switching the Microrouter On Warning - x Do not connect cables between any electrical hardware with the mains power switched on, since this could seriously damage components inside your CNC machine. Warning - x Never attempt to access the electronic hardware systems of the machine with the mains power switched ON.
4: Switching the Microrouter Off Warning - x Never attempt to access the electronic hardware systems of the machine with the mains power switched ON. Follow these instructions to switch off your Microrouter: 1) Wait for the Microrouter to fully complete any machining or processing of any operational instructions. 2) Open the safety guard door and remove any finished parts from the working area.
4: Part Manufacture Checklist and Tool Changing Checklist. Before beginning to manufacture your part, check to see that the following tasks have been completed: • Billet mounted and secure. • Tools prepared and numbered ready for use (according to your CNC file). • Safety guard door closed. • CNC file loaded and checked via simulation. • Workpiece and Tool Offset files configured or loaded. • Machine homed (datumed).
4: Part Manufacture Overriding the Spindle Speed and Feedrate Spindle speed override control. Feedrate override control. Emergency stop button. The table vacuum pump switch, emergency stop button, spindle speed and feedrate override potentiometer controls are mounted on the front control panel, located on the right side of the machine cabinet.
4: Part Manufacture Table Vacuum Pump & Emergency Stop Note - x Denford recommends that the vacuum cleaner used for dust extraction should have a minimum power rating of 500 watts. Cyclonic models, such as the Dyson, are not suitable for use with the dust extraction system. Note - x Activating an emergency stop will also trigger the interlock guard switch. This will prevent a closed safety guard door from being opened. Table Vacuum Pump Control.
5: Performing a Tool Change Standard Tool Change System. The tool change system, supplied as standard with the laminate trimmer on your Microrouter, comprises of four elements: i) The laminate trimmer threaded shaft, bored to allow fitment of the cutting tool and collet assembly. ii) The tapered, tubular, split metal collet, used to hold the cutting tool. iii) The cutting tool. Your microrouter must only be used with standard 1/4” or 1/8” shank routing bits, capable of running safely at speeds of 26,500RPM.
5: Performing a Tool Change Safety First ! - x Before beginning a manual tool change operation, we recommend you home all three machine axes. When all three machine axes are at their home positions, the maximum amount of free space will be available in the working area, allowing easier access to the tool holder and the easy change collar. Never open the safety guard door and enter the working area when the spindle or machine axes are moving. Note - Performing a Manually Requested Tool Change.
5: Removing the Laminate Trimmer from the Machine Head Safety First ! - x The easiest method of performing a tool change is to remove the laminate trimmer from the machine head, since the brush guards mounted around the base of the machine head prevent easy access to the laminate trimmer shaft. Tools required: • 5mm allen key (supplied). x To remove the laminate trimmer: Never open the safety guard door and enter the working area when the spindle or machine axes are moving.
5: Removing the Laminate Trimmer from the Machine Head Location - x Look at front of machine head. 2) Lift up the front brush guard to gain access to the laminate trimmer clamping bracket allen bolt. Above: Lift the front brush guard. Location - x Look at front of machine head. Above: Laminate trimmer clamping bracket allen bolt (circled). 3) Release the laminate trimmer clamp, using the allen bolt located on the front left side of the clamping bracket.
5: Setting Tools in the Laminate Trimmer Safety First ! - x Your microrouter must only be used with standard 1/4” or 1/8” shank routing bits, capable of running safely at speeds of 26,500RPM. Safety First ! - Caution. If the cutting tool has been recently used, it may still be HOT. The easiest method of performing a tool change is to remove the laminate trimmer from the machine head.
5: Setting Tools in the Laminate Trimmer continued... b a c Position the first multi-use spanner around the locking nut on the end of the laminate trimmer shaft (use the conventional spanner end). Position the second multi-use spanner around the fixture on the spindle motor shaft (use the C segment end). Position this spanner in the opposite direction to prevent the spindle from rotating as the locking nut is refitted (see below). Multi-use spanner around locking nut.
5: Refitting the Laminate Trimmer to the Machine Head Safety First ! - x Never open the safety guard door and enter the working area when the spindle or machine axes are moving. Location - Tools required: • 5mm allen key (supplied). To refit the laminate trimmer: 1) Check that the clamping bracket hole is loose enough to accept the laminate trimmer body.
5: Refitting the Laminate Trimmer to the Machine Head Location - x 3) Close the front brush guard. Look at front of machine head. Above: Close the front brush guard. Location - Look at left side of A slideframe assembly. x 4) Push the laminate trimmer power cable into the socket on the fixture at the top of the Z axis slide. Check that the laminate trimmer power cable will not interfere with any moving part of the machine. Left: Plug power cable into socket.
6: The Work Holding Clamp Rail Components The easiest method of holding large, flat workpieces in the working area of the Microrouter is using a series of work holding clamp rails. Each clamp fits between the front and rear X axis sliderail frames and grips the workpiece in a similar way to a G-clamp or vice. Additional clamps can be fitted between the X axis sliderails to give support to longer or thinner workpieces.
6: Assembling the Work Holding Clamp Rails To assemble each clamp rail: 1) Place the long, deep, U shaped section upside down, on a flat workbench, so the bottom of its channel is facing upwards. Place the shorter, shallow, U shaped section on top, so the bottom of its channel is facing down. Position this U shaped section so the single holes at each end align with the inner thread holes of the lower U shaped section.
6: Assembling the Work Holding Clamp Rails To fit the clamp rails in the Microrouter working area: 1) Position the clamp rails inside the machine, between the front and rear X axis sliderail frames. Align the clamp rails at right angles to the X axis sliderail frames. Rear X axis sliderail frame. Clamp rails. Front X axis sliderail frame. 2) Slide the bottom U shaped section of the clamp rail assembly onto both the front and rear X axis sliderail frames, using the two slots cut into the channel ends.
6: Using the Work Holding Clamp Rails Note - x Always use at least 2 clamp rails to clamp the workpiece. Additional clamps should be used to support longer or thinner workpieces (ensure these clamps are positioned in areas where no machining will occur). To clamp the workpiece: 1) Adjust the spacing between the upper and lower clamp rails, if necessary, so sufficient areas of the workpiece can be securely clamped.
6: The Vacuum Table Components The vacuum table is a fully assembled, self adjusting, lightweight vacuum clamping bed. The suction required for holding both the workpiece on the vacuum table and the vacuum table in position on the Microrouter floor, is provided by the pump located inside the base of the Microrouter cabinet. Upper rubber gasket (provides the seal between the workpiece and the vacuum table).
6: Preparing the Microrouter Working Area Although the vacuum table itself is supplied fully assembled, the Microrouter must be prepared before the vacuum table can be used: 1) Ensure the microrouter floor is clean and free from any dust and debris. This will help ensure a strong vacuum can be created between the rubber gasket on the vacuum table and the Microrouter floor.
6: Fitting and Using the Vacuum Table To operate the vacuum table: 1) Place the vacuum table on the Microrouter floor, with the multiple air valves and cells facing upwards, so the hole in the centre of the Microrouter floor is completely covered. Position the vacuum table so this hole is completely covered. Note - x Run the integrated vacuum pump only when using the vacuum table.
6: Fitting and Using the Vacuum Table 3) Place the workpiece onto the upper surface of the vacuum table, to cover as many complete cells as possible. Push the workpiece down to open the ball valves in each of the covered cells, engaging the vacuum. Sample workpiece. 4) The vacuum suction will hold the workpiece securely on the vacuum table. Push the side of the workpiece to see if it is held firmly. Do not lift the workpiece, since this will break the vacuum seal.
7: Maintenance Schedule and Charts Maintenance Schedule. Daily • Clean and remove any swarf. • Check that all the sliderails and leadscrews are lubricated. • Clean the tooling and laminate trimmer (machine head). Weekly • Clean the machine. • Check all exposed screws and nuts for tightness. • Lubricate all sliderails and leadscrews. Biannually • Check the condition of any electrical connections. • Check and clean tooling collets. • Check all cables for kinks and breaks.
7: General Work Area Cleaning Safety First ! - x Never open the safety guard door and enter the working area when the spindle or machine axes are moving. Safety First ! - x Caution. If the cutting tool has been recently used, it may still be HOT. Safety First! - x Warning. The silicone lubricant aerosol is extremely flammable. Never use the silicone lubricant aerosol near a naked flame, on any other machine, or for any other purpose.
7: Lubrication Areas on the Microrouter Safety First! - x Warning. The silicone lubricant aerosol is extremely flammable. Never use the silicone lubricant aerosol near a naked flame, on any other machine, or for any other purpose. Carefully read and follow any instructions or notices included with the aerosol. Wear safety glasses and a suitable respiratory mask when using the aerosol.
7: Lubrication of Leadscrews X Axis Leadscrew Lubrication. The X axis has two leadscrews, fitted to the front and rear slideframe assemblies. The first leadscrew is visible on the front slideframe assembly. The second leadscrew is located at the back of the machine cabinet, partially hidden from view by the panel on the slideframe assembly. Run the machine head fully to the right, to gain access to the left end of both leadscrews. Spray lubrication directly onto the exposed surfaces of the leadscrews.
7: Lubrication of Leadscrews Y Axis Leadscrew Lubrication. The Y axis has one leadscrew, fitted between the bases of the front and rear A slideframe assemblies. Do not confuse the leadscrew with the two sliderails, which also lie along the same plane. Run the machine head fully to the back, to gain access to the front end of the leadscrew. Spray lubrication directly onto the exposed surface of the leadscrew. Run the machine head fully to the front, to gain access to the opposite end of the leadscrew.
7: Lubrication of Leadscrews Z Axis Leadscrew Lubrication. The Z axis has one leadscrew, fitted between the upper and lower slideframe assemblies. Do not confuse the leadscrew with the two sliderails, which also lie along the same plane. Run the machine head up fully, to gain access to the bottom end of the leadscrew. Spray lubrication directly onto the exposed surface of the leadscrew. Run the machine head down fully, to gain access to the opposite end of the leadscrew.
7: Lubrication of Sliderails X Axis Sliderail Lubrication. The X axis has two sliderails, fitted to the front and rear slideframe assemblies. Both sliderails are located directly under and running parallel to the leadscrews. The first sliderail is visible on the front slideframe assembly. The second sliderail is located at the back of the machine cabinet, partially hidden from view by the panel on the slideframe assembly.
7: Lubrication of Sliderails Y Axis Sliderail Lubrication. The Y axis has three sliderails, fitted between the bases of the front and rear A slideframe assemblies. One sliderail is located at the top of the A slideframe assembly. The two remaining sliderails are located at the base of the A slideframe assembly, either side of the leadscrew, running parallel with the leadscrew in the same plane. Run the machine head fully to the back, to gain access to the front end of the sliderails.
7: Lubrication of Sliderails Z Axis Sliderail Lubrication. The Z axis has two sliderails, fitted between the upper and lower slideframe assemblies. The sliderails are located either side of the leadscrew, running parallel with the leadscrew in the same plane. Run the machine head up fully, to gain access to the bottom end of the sliderails. Spray lubrication directly onto the exposed surface of the sliderails. Run the machine head down fully, to gain access to the opposite end of the sliderails.
7: Cleaning the Thrust Bearing Couplings Location - x X Axis Thrust Bearing Coupling. Look at right end of rear slideframe assembly. Thrust bearing coupling. Photo shows the view looking at the thrust bearing, with the rear machine access panel removed. Location - x Using a soft bristled brush, carefully clean dust and debris away from the thrust bearing coupling, to an area where it can be removed using a vacuum cleaner.
7: Cleaning the Datum Microswitches X Axis Datum Microswitch. The microswitch defining the X axis datum is positioned on the right end of the rear X axis slideframe assembly, when viewed from the front of the machine. The microswitch itself is hidden from view by the extruded metal section, used to cover the drivebelt that connects the front and rear X axis leadscrews. In order to reach the X axis microswitch and trigger bolt, you must remove the access panel at the rear of the machine (see photo below).
7: Cleaning the Datum Microswitches Y Axis Datum Microswitch. The microswitch defining the Y axis datum is positioned at the base of the rear Y axis A slideframe assembly, when viewed from the front of the machine. The microswitch itself is hidden from view by the A frame itself. In order to reach the Y axis microswitch, you must remove the access panel at the rear of the machine (see photo below). Location - x Look behind rear A slideframe assembly.
7: Cleaning the Datum Microswitches Z Axis Datum Microswitch. The microswitch defining the Z axis datum is positioned inside the box section, on the top of the upper slideframe assembly. Using a soft bristled brush, carefully clean dust and debris away from the microswitch, to an area where it can be removed using a vacuum cleaner. If the microswitch is being cleaned with the Z axis at its datum position, take care not to disturb the trigger bolt on the top of the machine head casing.
7: Laminate Trimmer Maintenance Safety First ! - x Caution. Wear safety glasses and a suitable respiratory mask whilst cleaning. If the cutting tool has been recently used, it may still be HOT. Daily. Unplug the power lead from the laminate trimmer motor, at the junction on the upper slideframe box section.
8: Accessing the Electrical Panel Warning - x Never attempt to access the electronic hardware systems of the machine with the mains power switched ON. The Microrouter electronics are located in the right end of the machine. Using a 4mm allen (hex) key, remove the eight bolts, then withdraw the cover plate, to gain access to the electrical panel, as shown below. Note that hazardous voltages can still exist immediately after switching off the power.
8: Layout of the Electrical Panel - Note x The Electrical Diagrams for your Microrouter are not included in this manual - they are delivered separately in the standard equipment box supplied with your machine. Further electrical schematics are available on request. The photo below labels all important areas on the Microrouter electrical panel. Please note that the layout of your electrical panel may differ from the photo, depending on components and options fitted to your Microrouter.
8: The DenStep Motion Control Board The DenStep motion control board is mounted in the top left-hand corner of the electrical panel. It controls the motors that drive the three CNC machine axes. Seven Segment LED Display. Fuse. LED Status and Fault Display. The LED display is mounted on the left side of the DenStep motion control board. Display. Meaning. 0 No comms board address fault. Servo power off. 8 Servo power up and idle. Cam profiling (subscript symbol). Cam table (superscript symbol).
8: The Spindle Drive Board Two Spindle Drive Status LEDs. The spindle drive board, mounted in the bottom right-hand corner of the electrical panel, controls the motor for the programmable spindle. Fuse. Spindle Drive LED Status. The two spindle drive status LEDs are mounted in the top left-hand corner of the spindle drive board. Display. Meaning. ON LED Spindle drive board operational.
9: Technical Support Denford Limited provides unlimited telephone and e-mail Technical Support on this CNC machine to registered users. On-site visits by our engineers may be chargeable. Please refer to the information held in your separate Warranty pack, for specific details. Before contacting Denford for support, please read your hardware and software manuals and check the FAQ section on our website.
9: Troubleshooting Note - x Your screen may display the message "Error 50 Mint 3.28 Disconnect" (or similar, depending on the hardware fitted). Note - x The password used to access the "Machine Properties" window can be changed by the user. Remember that the default password listed here will not be recognised if you have changed it. If you change any passwords, we recommend you make a note of them in the Notes section in this manual.
9: Troubleshooting VR CNC Milling Software Communications Troubleshooting continued... 5) In the “Machine Properties” window, click the “Communications” property title. Change the “COM Port” setting to match the number of the COM port being used by your pc. Note that the hardware resources ( IRQ. etc.) are those specified in the Windows Control Panel. The “Baudrate” must be set to read “19200”. Baudrate is the speed at which data can be transferred through your COM ports.
9: Troubleshooting The part is being cut at an incorrect depth : Check the validity of the following: 1) The Z value entered in the tool length offset. 2) The Z value entered in the workpiece offset file. 3) The number (size) used for defining the depth of cut used in your CNC program. 4) The sign (+ or -) used for defining the depth of cut used in your CNC program. If your workpiece datum is aligned with the upper surface of your billet, any Z values cutting into this billet will have a minus sign.
10: Specification of Microrouter CNC machine Standard Equipment: • Microrouter CNC machine. • Quick release interchangeable laminate trimmer. • CNC machine control operating software. • Installation, maintenance and instruction manuals. • Set of maintenance tools and spare parts list. • Machine commissioning and basic instruction. • Worklight. • Dust collection system (vacuum not included). • Machine operation training (UK Only). Mechanical Details: • Accepts A3 sized material.
10: What is a Part Program? A Part Program is a list of coded instructions which describes how the designed part, or component, will be manufactured. The part program is also called the CNC File. These coded instructions are called data - a series of letters and numbers. The part program includes all the geometrical and technological data to perform the required machine functions and movements to manufacture the part.
10: Composition of a Part Program A component is designed using a CAD/CAM software package, such as Mill CAM Designer. The CAD/CAM software package automatically generates the part program, including all the G and M codes required to manufacture the component. Part Program example (Mill CAM Designer - triang.MCD) (3/3/1997) (metric) (Post fanucm:1.
10: G Codes List Note - x G codes from group Ø are non-modal (they must be programmed into every program block when required). All other G codes are modal (they remain active through subsequent program blocks, until replaced or cancelled by a G code from their particular group). The G codes indicated by an asterisk (*) are reactivated as defaults when the machine started. Note - Not all G codes may apply to your CNC machine. G Code. Group. Function.
10: M Codes List Note - x Not all M codes listed are available, all M codes marked with an asterisk (*) will be performed at the end of a program block (ie, after any axis movement). 74 - Appendix - Section 10 Note - Not all M codes may apply to your CNC machine. M code. Function.
10: List of Program Address Characters N - Program Sequence (line) number. X - Primary motion in X axis. Y - Primary motion in Y axis. Z - Primary motion in Z axis. G - Preparatory functions. I - Incremental distance parallel to X axis. J - Incremental distance parallel to Y axis. K - Incremental distance parallel to Z axis. R - Radius. M - Miscellaneous functions. T - Tool numbers. S - Spindle speeds. F - Feed rates.
10: Denford Directives Directives are program terms defined by Denford Limited. They are used to help generate the 2D and 3D graphics used by the machine controlling software. [BILLET This directive allows a billet that appears in a simulation window to be given a size. The billet definition should be placed at the start of a program, after the units of measurement have been set. Example: G21 [BILLET X1ØØ.Ø Y9Ø.Ø Z2Ø.
10: Denford Directives [TOOLDEF This directive sets the length and diameter of a cutting tool. The length of a tool is the distance from the spindle nose to the bottom of the cutter. Example: G21 [TOOLDEF T1 D8 Z65 This example defines tool number 1 as being 8mm in diameter, and 65mm long. [STEP This directive runs an on-screen program in single steps.
10: Understanding Offsets What are offsets? Offsets are a collection of numerical values used to describe the location of the workpiece datum. The moveable workpiece datum defines the zero point on our workpiece (the material we want to machine). This is the starting point for any cutting co-ordinates supplied by the machine controller.
10: Understanding Offsets Where should I position the workpiece datum on my billet? This depends on the position of the part datum set in your CNC program. The part datum is the zero reference, or starting point, used when plotting all the co-ordinates that describe the shape of your design. The part datum could have been set by the programmer, when manually writing the CNC program from a traditional engineering drawing, or automatically set by a CAD/CAM software package.
10: Configuring a Workpiece Offset The workpiece offset file contains three values, used to describe the location of your workpiece datum. They determine how much you want to shift the zero reference position of the CNC machine along the X, Y and Z axes. However, if your CNC file uses two or more tool profiles, the workpiece offset file will not account for the difference in length between the tools.
10: Configuring a Tool Length Offset The tool length offset files each contain a single Z value. A separate tool length offset file must be configured for every tool we want to use. They allow us to establish a common workpiece datum position, no matter what length of tool is used with the CNC file. Select a point on your billet that can be reached by all the tools you intend to use. All tool length offsets are configured against this common tool offset reference point.
10: Configuring a Tool Length Offset Move the Tool over the chosen Tool Offset Reference Position. Take care not to damage the cutting tip, when manoeuvring the tool. In this example, the tool reference position has been chosen as the upper surface of the billet. This position can be easily reached by all the different tool profiles we intend to use with the CNC file. The cutting tip just touches the surface of the billet. Billet. Laminate Trimmer (Machine Head). Billet.
EC Declaration of Conformity The responsible person ....................... Mr J.M. Boyle. Business Name ................................... Denford Limited. Address ............................................... Birds Royd, Brighouse, West Yorkshire, HD6 1NB, United Kingdom. Declares that the machinery described: Manufacturer ....................................... Denford Limited. Model Name ........................................ Microrouter Series CNC Machine. Serial Number ...........................
Back of the EC Declaration of Conformity Certificate.
Microrouter Series Noise Level Test Results Test Report No: NL - NR 1 - Ø1. Machinery Manufacturer: Denford Limited. Machinery Type/Model: Microrouter Series. The Microrouter can be supplied with various options, including a vacuum table and dust extraction. In both cases, a “Yorkleen Woodvac WY1” is supplied for this purpose. The test was carried out with and without these options. Equipment: Meter ref. “Realistic” 42-3Ø19 (last calibrated 30/11/98) - 1 off. Denford Microrouter CNC machine - 1 off.
Back of the Microrouter Series Noise Level Test Results Certificate.
11: Glossary ABSOLUTE ......................... In absolute programming, zero is the point from which all other dimensions are described. ALLEN HEAD ...................... A hexagon shaped hole on the head (top) of a set screw. These are tightened and loosened using allen keys/wrenches. ARC ..................................... A portion of a circle. AUTOMATIC CYCLE ..........
11: Glossary DRIVE .................................. The controller unit for a disk system. DRY RUN ............................ An operation used to test how a CNC program will function without driving the machine itself. DWELL ................................ A programmed time delay. EDIT ..................................... The mode used for altering the content of a CNC program via the Desktop Tutor or qwerty keyboard. END OF BLOCK SIGNAL ...
11: Glossary MACHINE DATUM .............. A fixed zero reference point set by the machine manufacturer. The machine datum is used to define the co-ordinate based grid system of the CNC machine. All machining co-ordinates originate from this point. However, this point can be temporarily moved using the machine offset facility. MACHINE OFFSET ............ The workpiece offset file used with VR and real CNC machines. MDI ......................................
11: Glossary TRAVERSE ......................... Movement of the cutting tool through the 3 machine axes between cutting settings. TXT ...................................... Standard Windows text only file, extension ".txt". WORK (WORKPIECE) ........ The actual material being milled. The work is sometimes referred to as the billet or stock. WORKPIECE DATUM ......... Used as a zero reference point on the real billet. All machining co-ordinates originate from this point, when offset files are used.
Index 12: Index A F Address characters listing ................................. 75 Advantages of CNC .......................................... 8 Axis definitions ................................................... 26 FAQs ................................................................... 67 Feedrate override ............................................... 30 C G codes listing .................................................... 73 General layout of machine ................................
12: Index O S Offset configuring tool length ................................... 81 configuring workpiece .................................. 80 Offsets description ..................................................... 78 Operation (of machine) axis definitions .............................................. 26 emergency stop ........................................... 31 feedrate override ........................................... 30 flowchart ........................................................
12: Notes Use this page to make a note of any parts of the software you have changed or configured, for example, common tooling set-ups, machine parameters, changes to installation paths or passwords etc.
12: Notes 94 - Index - Section 12 Microrouter CNC Machine User's Manual
