Xlmill Manual

ABOUT THE MANUAL
The manual guides the correct procedures for installing and operating the MTAB XLMILL
machine. All the installation process should be carried out out by MTAB approved personnel.
This manual provides installation and maintenance guidelines for the XLMILL that performs
drilling, boring, reaming, pocketing, grooving, threading, parting, roughing, chamfering, tapping
of circular and rectangular work pieces, using CNC programming and operating software.
The XLMILL is specifically designed for Education and Training, and is manufactured
according to industrial standards. The Mill is capable of cutting resistant materials and is totally
enclosed by high visibility guard.
If you have any doubts and/or questions regarding the specifications, features and
operations of the machine, Please contact customer service at MTAB.
COPYRIGHT
No part of this publication may be reproduced in any form, without the prior permission of
MTAB. MTAB holds the right to modify or change an y part of the document without any notification.
The authorized user of this manual shall acquire no rights in resp ect of trademarks or other intellectual
property rights referred to herein which are and shall remain the property of the owner thereof
MTAB ENGINEERS (P) LTD.

17/1, Thanikachalam road,
T.Nagar, Chennai 600017,
Tamilnadu, India.
Tel: 24345867 /24340738 /24348590
Fax: 91-44-24344826 /24337655
E-mail: mtabd3.vsnl.net.in
Web site:www.mtabindia.com
Safety notices
This Manual contains notices that are intended to ensure your personal safety and to avoid
any material damage. The notices are highlighted by a warning triangle and, depending on the
degree of hazard, represented as shown below:
Caution/Precaution
Indicates that minor personal injury or material damage may result, if the appropriate precautions
are not taken
Note
Is used to draw your special attention to important information on the product, handling of the
product or the corresponding part of the documentation.
Table of contents
1. Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Introduction of the Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Description of XLMILL Machine . . . . . . . . . . . . . . . . . . . . . . 5
Operating Procedure for non ATC Machines: . . . . . . . . . . . . . . . . . . . . 7
Back view of XLMILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4. Structure and specifications: . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

5. Machine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Unpacking of XLMILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..16
UpLifting of XLMILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Requirements for Machine Connection . . . . . . . . . . . . . . . . . . . . . . . . 18
6. CNC TRAIN Installation procedure . . . . . . . . . . . . . . . . . . . . .19

Installation of the security Dongle on the parallel port of the CPU . . .22
7. Machine Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8. Software Operating Procedure . . . . . . . . . . . . . . . . . . . . . . . . 29
Getting started with CNC Train. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Selection of Machine Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Main Menu Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Procedure for machining the sample program . . . . . . . . . . . . . . . . . . 48
9. Exercises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
M codes . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . 59
G codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Sample Programs . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 71
10. Maintenance Procedure: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

11. Trouble Shooting: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
CNC Machine XLMILL control side trouble Shooting: . . . . . . . . . . .84
12. Control Panel Layout . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . 86

13. ElectricalDrawing . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . 87
14. Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Safety Precautions
XLMILL User Manual
1. Safety Precautions
These safety instructions are intended to prevent hazardous situations and/or equipment damage.
These instructions indicate the level of potential hazard by labels of Cautions, Warning orDanger.
The machine has safety devices fitted to pr otect the machine and the operator from unexpected
accidents.
i. Tidiness
Do not place objects that interface with the guard or during the operation of the machine,
Do not place objects ON or around the machine.
ii. Power Source
Ensure that correct cable is used for power source.
Ensure that the earth connection is proper.
Turn OFF the isolator switch on the control box immediately when power fails.
Ensure whether the power is switched OFF at the end of the work.
Ensure whether the machine is switched OFF before maintenance.
iii. Lubrication
Refer maintenance section for safety during lubrication.
.
Check the status of slideway lubrication daily
Safety Operation Procedure:

Always wear clothing that is suitable and safe for operating the machine.
Secure the work piece tightly in the fixture
Ensure that the tools are tightly fixed in the tool holder.
Close the safety guards during machine operation.
Use the simulation to avoid machining errors.
Do not clean the machine or its attachment when the machine is in operating condition.
Do not operate the machine when the control box is opened.
Switch OFF the isolator before opening the electrical cabinet. Do not attempt to clean the
machine or remove the swarf when the machine is in operating condition.
Press the emergency stop, on the front of the machine, to cut the power supply to the
spindle and the axes drives, during emergency.
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Safety Precautions
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Common Safety Precautions:

The Compatibility of pneumatic equipment is the resposibility of the person who designed
the pneumatic system or decides its specifications. The product specified here is used for Milling
operating condition.The specifitions or analysis and/or tests to meet your specific requirements are;
Caution: Operating error could result in injury or equipment damage.
Warning: Operating error result in injury.
Danger: In extreme conditions, there is possibility for some serious injury to occur.
Operating Environment
Do not use in environment where the products are directly exposed to corrosive gases,
Chemicals, salt water etc.
Do not expose the products to direct sunlight for an extended period of time.
Do not expose the machine in heavy vibrations and/ or shocks.
Do not mount the product in locations, exposed to radiant heat.
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Introduction and Description
XLMILL User Manual
2. Introduction of the Machine

A 3axes CNC bench-milling machine with Fanuc Emulated Control Programming Software. The
Software incorporates major functions and facilities used on industrial controller with further option of
linking to CAD/ CAM and FMS (Flexible Manufacturing System)
Front View of XLMILL
Figure 2
The manual provides the installation and maintenance guidelines for the XLMILL that performs
drilling, reaming, pocketing, grooving, parting, roughing and chamfering of circular and rectangular work
pieces, using CNC programming and operating software. The Mill is spec ifically designed for Education
and Training, and is manufactured in accordance to the industrial standards.
Features of the XLMILL

Specifically designed for Education and Training
Manufactured in accordance to industrial standards
Fully enclosed high visibility guard
Standard Equipments Supplied
Main Supply: 220V 2% 50 cycles and 10 A Single phase
Manual single shot central lubrication system.
Set of maintenance tools and spare parts list
Installation, maintanence and instruction manuals.
Industrial type keyboard.
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Introduction and Description
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Optional Equipments
Automatic Tool Changer(ATC)
Hydro- Pneumatic Vice
Automatic Door
Work Bench software.
Software supplied:
CNCTrain software CD
Tools Kit:
Collet chuck ISO 30/A45 RD 25 with Pull Stud
Collet chuck ISO 30/A45 RD 16 with Pull Stud
RD 25 Collets Dia 5,6,8,10,12,16 mm
RD 25 Collets Dia 3,4,5 mm
2 Lipped Cardibe slot Mill for facing shank dia 16mm
Clamping Kit
Set of HSS Mill Dia 5, 6, 6, 6, 8 mm
Set of HSS Mill Dia 10, 12, 16 mm
HSS Slot Drills Dia 5, 6, 6, 6, 8 mm
HSS Slot Drills Dia 10, 12, 16 mm
Maintanence Tools
Allen Key
Screwdriver set
Double Ended Spanner
C Spanner
Spanner MorBox Type -E25
Spanner E 16
Oilcan with oil
Oil Gun
Additional offline programming software
PC workstation
Fuses -1set /8Nos of fuse Pack
FMS equipment and system integration.
Machine Cover
Datum Plate and Billet Clamp
Lubrication Pump
PU 8 Hose
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Description of XLMILL Machine
XLMILL User Manual
3. Description of XLMILL Machine

Full View of XL Mill
Figure 3.1
The XLMILL is totally enclosed by a high visibility guard. The XLMILL Machine inspection and functions are carried out in the following schedule.
i Hydro Pneumatic Pressure intensifier with Single Acting Cylinder
ii ATC Automatic Tool Changer
iii Hydro Pneumatic Vice
i. Hydro Pneumatic Pressure Intensifier with Single Acting Cylinder

Hydro pneumatic pressure intensifier is cylinder shape and is present on the extreme left of the
machine bed. This intensifier contains oil and air to produce the Hydro pneumatic pressure. This pressure
is used to give the movement to the "Hydro pneumatic" vice.
Due to the Hydro pneumatic pressure the jaw in the vice will move in -X, +X axis to either clamp or
unclamp the billet.
Hydro - Pneumatic Intensifier
Figure 3.2
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ii. Hydro Pneumatic Vice:
Figure 3..3
In Hydro Pneumatic Vice, the cylinder is connected to the Pneumatic Intens ifier with a
tube.
Movable jaw in the vice helps in holding the billet.
Fixed jaw is immovable in this device.
iii. ATC (Automatic Tool Changer)
ATC Automatic Tool Changer rotates with the help of a motor.
ATC contains 6 station and it can load 6 tools at a time.
The cutting tools is used in an ATC to fitted in seperate tool holders. Each tool holder shunk
has a pull stud which is used to clamp the tool holder firmly in the spindle.
This pull stud should be checked weekly.
ATC (Automatic Tool Changer)
Figure 3.4
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Description of XL MILL Machine
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View of ToolHolder
Figure 3.5
Tool Holder is used to hold the tool
Operating Procedure for non ATC Machines:

Procedure for fixing the tool in the spindle:
The tool holder in the spindle is opened and closed using a lever with key, supplied along with the
machine.
Lever with Key
Figure 3.6
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To fix a tool, the lever with key has to be fixed in the socket on the spindle head.
Figure 3.7
Insert the Key in the socket on the spindle head with the help of the lever.
Figure 3.8
i. Move the lever towards the backside of the machine to open the tool holder.
ii. Then insert the tool in the spindle.
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Figure 3.9
After fixing the tool move the lever in the other direction to lock the tool.
Figure 3.10
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Description of XLMill Machine
XLMILL User Manual
Back view of XLMILL
Figure 3.11
Air Filter Regulator and Lubricator
Figure 3.12
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DRAIN
Maximum pressure for air regulator is 9.9 Kg F / cm (150 lbs sq).The Op erating pressure 100lbs
sq."(6.9 Bar). Check the main supply pressure before adjusting pressu re at the regulator. Air filters on the
both side of the machine should be changed annually.
To adjust the pressure pull up the rotary control, un lock it from its current position. Turn the control to
clockwise to increase pressure, and anti-clockwise to decrease the pressure. Push the rotary control down
to relock it in its new position. Regu larly drain the water collected in th e filter bottle. The interval at which
this operation is required will depend on the type and condition of the air compressor being used.
The air Lubricator Oil - (Suitable)

Turn the front small adjusting screw clockwise to increase the oil flow, or anti-clockwise to decrease
the oil flow. Oil can be added to the resovior bottle by removing the black cap.
Layout for Back View of XLMILL ATC
Figure 3.13
Notes :
For Smooth running of the system, it is essential that the power supply is constant and stable
Emergency Stop:
Emergency Stop is used to avoid the eradication du ring the processment of the machine. The user can
use this emergency stop button only during the emergency requirement.
Push the emergency stop switch to stop the machin e and to release the emergency stop, turn the red
knob on the switch in clockwise direction.
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Structure and specification
XLMILL User Manual
4. Structure and Specifications:

Totally enclosed gantry-type machine, which combines the robustness of its structure with the quickness
of operation. All the transmission guides are well protected against dust and chip. The holding system of the
parts is carried out by means of an specification.
Full View of Machine Dimension
Figure 4.1
Inner view of Machine Dimensions
Figure 4.2
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Structure and Specifications
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Lengthwise Dimension 575MM.

Heightwise Dimension 520MM

Dimension of XLMILL
Figure 4.3
Siting of XLMILL
The XLMILL should be sited on a bench of robust construction to take the weight of the
mill.
Note : Ensure that sufficient room is allowed while sitting the mill, so as to enable smooth operation,
programming, and effective maintenence of the mill
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Structure and Specifications
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Capacity Diagram
Figure 4.4
Spindle Travel Over Table
Figure 4.5
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Structure and specification

Table 1: Specifications:
Table Size
360mm x 132mm
Travel X axis
225mm
Travel Y axis
150mm
Travel Z axis
115mm
Spindle to table Distance
70mm to 185mm
Spindle Column
110mm
Spindle Nose Taper
ISO 30
ATC
6 Stations
ATC - Maximum tool diameter
16mm
ATC Maximum tool length
40mm
ATC Direction
Bi Direction
Programmable Spindle Speed
150 4000 rpm
Table 2: Machine Specification
Programmable Feed Rate

X and Y axis
0 500 mm/min
Z axis
0-500 mm/min
Repeatability
0.01 mm
Table 2: Machine Specification
Programmable Feed Rate

Rapid Rate (X, Y and Z axis)
1.2 m/min
Axis Motors (Stepper motor)
200 Steps/rev
Machine Weight
170 Kg Approx
Machine Dimensions (LxWxH)mm.
1000 x 575 x 650
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Machine Installation
5. Machine Installation
Unpacking of XLMILL
Machine Packing consist of three packs,
"One for the machine

. for the controller box
"One
"One for the accessories.
UpLifting of XLMILL
Use crowbars to lift the machine.
Remove the outer wooden packings using claw hammer.
XLMILL is lifted using the crowbars, fixed under the clamps provided at the side of the cabinet. Ensure
that the machine is secure and bala nced while lifting. Always use correct lifting precautions in accordance
with the Health and Safety Regulations in your establishment .
Figure 5.1
Method of unpacking the XLMILL:

Once the machine has been sited to connect electrically, protective coatings must be removed to prepare
the machine for running.
The protective coating applied to the slideways and bright surfaces can be removed using a kerosene
based solvent. The coating must be removed from the slideways before any attempt is made to move
Once the protective coat is removed, all untreated surfaces should be coated with a light
smear of machine oil.
The protective plastic sheet on the windows should be removed and the glass and Perspex
should then be cleaned with an anti-static cleaner.
Temperature in that location should be 20 to 50C.
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Donts
Dont operate the machine before cleaning.
Dont use compressed air for cleaning (Like Air Gun).
Notes: It is highly recommended to operate the machine in a conditioned temperature
for better and constant accuracy
Leveling of XLMILL without Enclosed Guard

The XLMILL should be leveled by adjusting the hollow.
Rest the milling machine on an anti-vibration pad, before the machine is leveled.
The milling machine has been leveled to the cabinet prior to dispatch so it is only necessary
to level the machine with respect to the bench or table.
The XLMILL should be sited on a bench of robust construction to take the weight of the
mill.
Note : Ensure that sufficient room is allowed while sitting the mill, so as to enable smooth
operation, programming, and effective maintenence of the mill
Electrical Connection
Figure 5.2
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The electrical connection power supply is fed to the electrical control box, and fit in the back of the
machine cabinet , which in turn is connected to the milling machine.
Note:
Do not connect the cables between any electrical hardware with the main power switched ON
Since this could damage the hardware.
Requirements for Machine Connection

XLMILL Connection
Figure 5.3
Description of Connections
Connect the power cable from the Control box to rear portion of the XLMILL machine as
shown in the above diagram.
Connect the USB cable from the Control box to the Computer.
Connect the Control box mains supply (220/240v 1 phase) to power supply point on Stabilizer
and connect the Computer cable to the Stabilizer.
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CNC TRAIN Installation Procedure
XLMILL User Manual
6. CNC TRAIN Installation procedure

Insert the software CD in the drive.
Figure 6.1
Select My Computer and double click th e CD Drive to open the CNCtrainsetup.

CNC Trainsetup
Figure 6.2
The online instructions are shown below.

This image shows that the CNC Train Initializing Wise Installation Wizard
Figure 6.3
This process will start installing the CNC Train on your computer.
Click Next to continue the further setup program.
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Click browse to choose the destination folder and then click next to continue.
Figure 6.5
Next is selecting the program manager group, select it as CNC SIMULATION as shown below
Figure 6.6
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Click Next to start the installation.
Figure 6.7
Then the installation procedure starts.
Figure 6.8
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The system configuration will be updated.
Figure 6.9
Press Finish to complete the installation.
Figure 6.10
Installation of the security Dongle on the parallel port of the CPU

The following is the procedure to install or activate the security dongle.
i. Fix the security key in the parallel port of the cpu.
ii. Select C drive.
Figure 6.11
Enter in to the CNC TRAIN folder
Figure 6.12
Select the SECURITY folder
Figure 6.13
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Open the INSTALL Folder
Figure 6.14
Double click the sl2inst file. It is shown below
Figure 6.15
Click the INSTALL button
Figure 6.16
As soon as the Dongles driver is installed you will recieve the following messsage. Click OK.
Figure 6.17
Now the software is ready for the simulation as well as operation of the machine
Opening procedure:
As the installation is completed we can see the CNC TRAIN icon on the desktop and also in the programs
The software can also be opened by the following path as given below.
Start > Programs > CNC Simulation > CNC TRAIN.

(Or) to openup in shortcut method Press the CNC TRAIN icon in the desktop.
.
Figure 6.18
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7. Machine Link
Work Bench software installation:
This Work Bench software is use to link the machine with the computer
Install the Work Bench software by following the steps given below.
Insert the Work Bench software CD in the drive.
Double Click the setup installer to launch the installshield software in to the system.
Figure: 7.1
Setup: This Step shows prep aring to install the software
Figure: 7.2
Windows installer
Figure:7.3
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Click Next to continue the software installation .
Figure: 7.4
Click on the accept term in the license agreement, then click on next button.
Figure: 7.5
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Please Enter your information and click on Next Button to continue.
Figure: 7.6
Click Next to install to the Selected folder, or click change to install in a different folder.
Figure: 7.7
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Click on install button to install the settings, click on cancel to exit the wizard.
Figure:7.8
Now the InstallShield Wizard installs Mint Machine Center and Mint Workbench (5600).
Figure: 7.9
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Click finish to complete the installation and to exit the wizard.
Figure: 7 .10
XLMill Mex file:

Copy the Mex file and paste it in the location as given below
CNCTrain > metric > Mtab machine tools > milling
Figure: 7.11
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Software Operating Procedure
XLMILL User Manual
8. Software Operating Procedure

Getting started with CNC Train.
After installation the software operating procedure double click on the CNCTrain icon in the desktop.
Figure 8.1
Click Start > Menu Program > cnctutor > CNC simulation > CNC Train
Figure 8.2
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CNC Train opens the Fanuc Mill OM control In that Enter the password as MASTER in the Pass word Box and click ok..
Password Dialogue Box
Figure 8.3
Password
Note :
Password is not Case-sensitive.
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Selection of Machine Type
Click Here
Figure 8. 4
Click Fanuc O Milling from Control Type Menu to select the machining type. This selection is to run
either milling or turning.
Show MDI Panel:

It Play a vital role in the XL milling machine. It is used to type the Program in the GE Fanuc OM.
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Actual Screen for Milling
Figure 8. 5
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Selection of Machine Type:

Click Control Type Fanuc O Milling
Figure 8.6
Select Job/Tooling > Machine Settings
Change the Parameters in the Machine settings, Billet settings, Tool Offsets and Machine control as given,
below pages.
Finally for the Machine Link.
Goto Main Menu > Machine Options > Machine Link.
This Will Prompt you to the Machine Link.
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Main Menu Bars

The software operating methods and the functions of the main menu bar is as follows
Menu bar reference

i. File
ii. Edit
iii. Options
iv. Job/Tooling
v. Control Type
vi. Machine Options
vii. Help
File Menu:
Figure 8.7
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The main menu lists the set of sub-menus to perform several actions with programs.
Table 1: File Menus
Main Menu
Description
New CNC program
New CNC Program is used to type the program in the CNC editor
Load CNC program
This is used to open up the selected file
Save CNC program
Use to save the CNC program
Save As
Save and over write the program in another name.
Store Memory
Use to store the current in the active CNC control memory.
Edit File
Used to add the text file in the CNC Editor and amended
Save File
Use to save current file appears in the Editor Screen.
CNC Editor-RS 232
Is used to Edit the CNC Editor- RS 232
USB Port
Is used to Edit the CNC Editor- RS 232
Printer Setup
Shows the print setup in the Progamming Screen to print th current

file.
Printer
It is use to print the file
Stop
It is use to stop the running programs.
Load CNC Program
Figure 8.7.1
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Click File Menu and click the load Cnc program from the screen Editor.
Click File Menu < Save File
Figure 8..7.2
Edit:
Figure 8.8
The work procedure of Edit Menus is given below.
Table 2: Edit
Edit Menu
Description
Undo
Use to re-edit the deleted items.
Cut
Use to cut the selected items from the screen.
Copy
Use to copy the selected particulars from the screen.
Paste
Use to Paste the cutted or selected items in the screen.
Font
Contain several types of fonts use change the font type in the screen.
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Options
Options Menus explaination is given below,
Figure 8.9
"New Billet : It opens a new billet.

"Single Edit : It views the tool on the CNC Train simulation system.
"Dual Edit : Dual Edit mode is used for a Full Screen Editor and the second screen editor
for loading and copying routines from the CNC Part programs.
Job/ Tooling
Figure 8.9.1
"Full Screen: It Shows the Full Screen of the Editor Screen

"Set Colors : Set Colors sub menu is used to set the colors on the screen (or) Use to change
color.
Figure 8.10
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The Work procedure for the Job/ Tooling is shown below:

Machine Settings
Select the Job/Tooling from the main menu to set machine setting.The Following display
will appear on the screen.The machine parameter setting should be done USING the
displayed screen
Machine Setting Dialogue Box
Parameter settings
Minimum Traverse
Set the minimum traverse for all the axes. The value must be less than the min imum traverse value.
" Maximum Traverse

Set the maximum traverse for all the axes. The value must be greater than the
maximum traverse value.
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"Home Positions
Set the Home Positions for value for all the axes. These are the machine posi tions when the axes have mo ve to their datum switches
"Spindle
Sets the machine spindle to manual or automatic.
"Tool change calls

For manual tooling you should promptly en ter a tool at all tool change calls. If
rotary tool post is selected the tool will be automatically from the tool library.
"Home Switches
Tick this box if your machine has da tum switches and you want to axes to
Home to the datum switches
"Homing Speed
Machine type sets the Homing speed for the current.
"Machine File Name

Select the machine file name or doub le click on the list of existing parameters set, you can then change the requ ired parameters to suit. Loading an
exiting machine type will reset the parameters to the new settings.
Any changes you make will be automatically saved to disk
.
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Billet Settings
Figure 8.12
To Adjust Billet Settings Open up the Billet screen as shown above.
" Maximum Ranges:

These parameters are for firture development.
"X,Y.Z Shift
Work shift value are the distances from the positionto the billet
datum position. These values are automatically inserted when you
datum th tool
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"Offsets
Displays the current units of measurement. Switching units can only done
by the site license screen when you first run the software.
Auto Load Work Shift Offsets : Each CNC program stores its own work shifts offsets. If you
want to load these offsets when loadings a CNC programs ticks this option box. By deselecting this option you can load CNC programs
"Save Workshift Offsets : Save the current offsetin the current machine type settings file.
Selecting a new machine type loads the work shift for that machine.
" Load Work shift offsets : Loads the current work shift offsets for the active Machine
Type.
"Important : Use Tool 1 when settings the datum position. If you have Auto Tool offsets
ticked you do not have to datum the tools.
Imperial and Metric

Switches between Imperial nad metric. Metric or Imperial values are auto matically loaded when selecting this option.
"Billet Length: Set the billet length for a new part program
"Billet Width :Set the billet Width for a new part program:
"Billet Depth : Set the billet Depth for a new part program
"Billet X : (Simulation purpose only) : If the Datum position for
the X axis is not bottom left hand corner of the billet than
you can shift the datum position by typing in a value.
" Billet Y : (Simulation purpose only) If the Datum position for the X axis is not bottom
left hand corner of the billet than you can shift the datum position by typing in a value.
"Billet Z : (Simulation purpose only) : If the datum position for the Z axes is not the top
of the billet then you can shift the datum position by typing the value.
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Tool OffSets
Figure 8.13
Up to 99 tools can be stored in the tool offsets page with all the relevant information for each tool.A
library of tools for a particular machine type or for a part program can be selected and saved to disk.
"TOOLTYPE : This value is the type of tool being used, for example: End mill, Slot Drill
etc. A library of tool types is stored in the Select Tooling page.
"TOOLRAD : The radius of the tool for compensation is stored in this column. This value
depends on the programmer and the G41/G42 tool compensation that he is using.
"ACTUAL DIAM : This value is the actual value of the cutter diameter and will be used
in the simulation to display the tool.
Z LENGTH
This value is the z length offset.
"Option 1 : Type in the Z length offset in the relevant column. This method is suitable for
pre- set tooling.
"Option 2 : Move the tool to the top of the job in Jog Mode and double click in the relevant Z length offset column to automatically transfer the offset from the positional data.
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Note:
If AutoToolOffsets is selected then Z length offsets will not be used.
TOOL LENGTH
This value is the actual tool length.
" Option 1 : Type in the tool length by measuring the actual tool and placing the value in
the relevant column.
" Option 2 : Move the cursor to the cutter on the screen, press the left mouse button and
drag the tool up or down to the required length. The value will be automatically inserted
into the relevant Tool Length column.
CHUCK LENGTH
This value is the actual chuck length.
" Option 1 : Type in the chuck length by measuring the actual

.
chucks length and placing the value in the relevant column.

" Option 2 : Move the cursor to the chuck on the screen, press the
mouse on left button and drag the chuck up or down to the required
length. The value will be automatically inserted into the relevant Chuck Length column.
CHUCK TYPE
This value is the name of the chuck that you want to use. A library of chuck types can be created on the
Select Tooling page.
CHUCK WIDTH
Chuck width can be used in the same way as chuck length but specifies the chuck diameter.
Auto Tool Offsets

With the machine control software this option is not available. You must always set your tool offsets
when controlling a CNC machine tool. For simulation purposes tick Auto Tool Offsets if you want the off
sets to be calculated automatically. Untick this option to force the student to set tool offsets.
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Tool Selection:
Figure 8.14
View a Tool
The system comes with a selection of tools. To select a tool point to the tool name in the list box and
double click with the left button of the mouse. The relevant bitmaps will be displayed in the boxes.
Add a Tool: You can define and add your own tools by defining
the bitmaps and the tool geometry.
Delete a Tool : Highlight the tool name in the listbox and press
the Delete key on the qwerty keyboard. The tool name will be deleted
from the list.
Chuck List : Chuck bitmaps can be added and removed in the same
manner as the tool bitmaps.
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Machine Control Settings:
Figure 8.15
Machine Control dilogue box is use to set or arrange the machine control settings to their suitable
work. After completing the setting Click Ok.
Com Port Options 1 :
Figure 8.16
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The following box appear and change the set up value as shown in the parameter box(This setting is
only for the desktop Keyboard).
Com Port Options 2:
Figure 8.17
Control type
Figure 8.18
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MDI Panel :
MDI Panel is use on the screen to generate CNC programs by clicking the machine on the relavent button wtih the On - screen control.
Figure 8.19
Fanuc O Milling : Use to open up the milling job options.
Machine Options:
Figure 8. 20
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" Machine Link option :It is only available with machine software switches they link
between the computer and the CNC machine tool off/on.
" After connecting to the CNCmachine tool for the first time you can untick the machine
link and simulate to the CNC programs.This will allow you to test the CNC program before cutting the part on the machine. Next step, NextMoveST, NextMoveESB, Show Mint 328, Set Dnc/
Tutor omms Link, Set Machine Comms Link,
" Receive File, Send File : Use to Send and Recieve the particular through these files.
Procedure for machining the sample program

i. Editing the program
ii. Setting the tool and billet
iii. Simulation
iv. Machining the component
i. Editing the program.
CNC Program
O1111
G21 G94
G91 G28 X0 Y0 Z0
M06 T01
M03 S1500
G90 G00 X0 Y0 Z5
G172 P0 Q-1 R0 X-25 Y-35 Z-1 I20 J20 K0
G173 P80 S1500 R40 F100 B2000 J50 I.2 K.2 T1 Z5
G172 P1 Q-1 R0 X-25 Y-35 Z-1 I20 J20 K0
G173 P80 S1500 R40 F100 B2000 J50 I0 K0 T1 Z5
G90 G00 Z5
G172 P0 Q-1 R0 X15 Y-5 Z-1 I20 J20 K0
G173 P80 S1500 R40 F100 B2000 J50 I.2 K.2 T1 Z5
G172 P1 Q-1 R0 X15 Y-5 Z-1 I20 J20 K0
G173 P80 S1500 R40 F100 B2000 J50 I0 K0 T1 5
G90 G00 Z5
G170 P0 Q-1 R0 X-25 Y30 Z-1 I.1 J.1 K12.5
G171 P80 S1500 R40 F100 B2000 J50
G170 P1 Q-1 R0 X-25 Y30 Z-1 I0 J0 K12.5
G171 P80 S1500 R40 F100 B2000 J50
G90 G00 Z5
G170 P0 Q-1 R0 X25 Y-30 Z-1 I.1 J.1 K12.5
G171 P80 S1500 R40 F100 B2000 J50
G170 P1 Q-1 R0 X25 Y-30 Z-1 I0 J0 K12..5
G171 P80 S1500 R40 F100 B2000 J50
G90 G00 Z5
G91 G28 X0 Y0 Z0
M05
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M30
End
ii. Setting the tool and billet

"Select the Job/ Tooling Menu to Select the menu.
"Select any one of the tool and Click ok
"Select the Tool Offset Menu to set the Tool settings.
Enterlength
EnterWidth
Enter Depth
Figure 8.21
"Select Billet from the Job/Tooling menu and arrange the settings.
"Click Ok to Save workshift Offsets
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iii. Simulation:
Simulation of Milling the Billet. When starting the machine the machine link should be deactivated
Continuous Process of Simulation
Ending process of Simulation
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iv. Machining the Component

i. Clamping the Billet
ii. Check for machine settings
iii.Taking Tool Offset and Work Offset
iv. Running the Machine
Clamping the Billet. I
Method of fixing the Tool
Step 1 : Billet 100X100 is fixed in the table using clamp and jaws. Touch the work piece at
the lefthand side using dia 6mm cutter
Zero Point
Step 2 : Click X offset in the CNC Display screen to move the cutter in X axis Direction.
Press + button in the CNC control. Press Datum to move
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Movement of Tool towards Work Piece
Press X
Click Here
Step 3 : Press X again in the CNC display screen.
Moving Towards +Z Direction
Step 4 : Move the cutter in towards + Z direction
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Cutter in center
53mm
Step 5 : Move the cutter about 53mm. Place the cutter in center.
CNC Display Method

Press
Datum
Press
Figure 8.22
Step 6 : Press Datum and press X in CNC Display.
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Billet Setting Changes:
Change
X&Y
Shift
Figure 8.23
Step 7 : Go to Billet setting to change X axis shift from verification
Taking Y Offsets
Touch
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Step 1: Touch the front side of the billet

Step 2 : Click the Datum and press Y from the CNC Display screen
Figure 8.24
Step 3 : Move the cutter up in Z directionStep 4 : Move the cutter 53mm to place the cutter
in center.
Z direction
Place cutter in center
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Step 5 : Press Datum and Click Y from the CNC Display screen
Figure 8.25
Step 6 : Click Billet setting from the Job/Tooling menu and verify the settings.
Change
X Axis
Shift
Figure 8.26
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Tool Length Offset.
Step - 1 : Touch the top surface of the cutter by bringing the cutter down by moving the Z
axis..
Step -2 : Select Job/Tooling Menu to open the Tool Offsets. And double Click on the Z
Offsets column.And click Ok to continue.
Click and select

Tool type
0.
Figure 8.27
Step-3 : Click Auto in the simulaion screen. And press Cycle Start to finish up the work to
give the final output.
Figure 8.28
Step- 4 :Store the current CNC program in the active control memory todisk with its settings.
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9. Exercises
Introduction.
Each part program contains a number of different codes, the most important being the
collection of G and M codes. Essentially, these form the basic language used to describe
how a component will be manufactured, the order in which to carry out machining tasks,
when to change tools, how far to cut into the material etc.....
The helpfile is divided into three main sections, each with their own list of topics:
1) Basic Programming - This section builds progressively, using plain, easy to follow
text, to cover the general layout and commands of a part program. At the end of this
stage, the operator should be confident enough to tackle basic part programming.
2) G Codes - This section should be used as a reference guide, once the operator is
confident with the basics of programming. It contains detailed information, specific to
certain Preparatory Fuction commands used by the system.
3) M Codes - This section should be used as a reference guide, once the operator is
confident with the basics of programming. It contains detailed information, specific to
certain Miscellaneous Fuction commands used by the system.
List of M Codes
M (Program Stop).
M1 (Optional Stop).
M2 (End of Program).
M3 (Spindle Forward).
M4 (Spindle Reverse).
M5 (Spindle Stop).
M6 (Automatic Tool Change).
M8 (Coolant On).
M9 (Coolant Off).
M1 (Chuck Open).
M11 (Chuck Close).
M13 (Spindle Forward and Coolant On).
M14 (Spindle Reverse and Coolant On).
M25 (Tailstock Quill Extend).
M26 (Tailstock Quill Retract).
M3 (Program Stop and Reset).
M4 (Parts Catcher Extend).
M41 (Parts Catcher Retract).
M62 / M63 / M64 / M65 / M66 / M76 / M77 (Auxiliary Output Functions).
M98 (Sub Program Call).
M99 (Sub Program End and Return).
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M CODES:
M Codes (Miscellaneous Functions) - Introduction.
Miscellaneous functions, called M codes, are used by the CNC to command on/off
signals to the machine functions. ie, M3 - spindle forward (CW), M5 - spindle stop,
etc..... The functions allocated to lower M code numbers are constant in most CNC
controls, although the higher M code number functions can vary from one make of
controller to the next.
M00 Program Stop

M00 waits for EOB to be pressed.
M02 End of Program

M02 halt program execution
The spindle is turned off and the tool moves to the most positive position on the Z axis
M03 Start Spindle

An M03 instruction starts forward spindle motion. It requires a speed within the range 100 to 3000
RPM
Example : M03 S2200
The spindle should be switched on before any movement below the component surface.
M04 Reverse Spindle

An M04 instruction starts reverse spindle motion, it requires a speed within the range 100 to 3000 rpm.
Example : M04 S2200
The spindle should be switched on before any movement below the component surface.
M05 Stop Spindle

An M05 instruction stops spindle rotation.
It is good programming practice to issue an M05 before a tool change, and at the end of a program,
However this will be done automatically should you omit this instruction
M06 Change Tool

The M06 instruction causes the Fanuc to change to a different tool. The tool changing operation should
be done in the home position only.
Example: M06 T1
You can get tool length and diameter at the start of the program using the TOOLDEF directive. Only
for the simulation practice.
M08 Coolant On
M08 turns the coolant on.
M09 Coolant Off

M09 turns the coolant off.
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M10/11 Work Clamp Open/Close

M10 opens the work clamp
M11 closes the work clamp.
M13 Coolant Spindle Fwd

M13 turns the coolant on and starts forward spindle motion.
Example : M13 S1000
M14 Coolant Spindle Rev

M13 turns the coolant on and starts reverse spindle motion.
Example: M14 S1000
M19 Orientate Spindle

M19 orientates the spindle
M20 /21 ATC Arm In / Out

M20 moves the ATC arm in.
M21 moves the ATC arm out.
M22 / 23 ATC Arm Down / Up

M22 moves the ATC arm down.
M23 moves the ATC arm up.
M24/25 ATC Arm Clamping

M24 activates the ATC drawbar. [Tool release]
M25 releases the ATC drawbar. [Tool pick up]
M27 Reset Carousal

M27 can be used in the control panel.
The current carousel position is treated as position one.
Example : At the time of tool changing operation the screen will display the current station number
which is engaged for particular operation.
M32/33 Turret Indexing

M32 Clockwise rotation of turret
M33 Counter clockwise rotation of the turret
M38/39 Door Open /Close

M38 opens the door
M39 closes the door
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Input/ Output Commands for FMS

M62/65 Auxiliary output 1/2 on
M62 Sets Auxiliary output 1 on
M65 Sets Auxiliary output 2 on
M64/63 Auxiliary output 1/2 off

M64 Sets Auxiliary output 1 off
M63 Sets Auxiliary output 2 off
COMMANDS DESCRIPTION
These commands are available in the machine side
The Robot inputs can be switched on by sendi ng the output signal from machine side to Robot
side as a input signal.
M76//67 Waiting for Auxiliary input 1/2 on

M76 waiting for Auxiliary input 1 on
M67 waiting for Auxiliary input 2 on
NOTE: M76/67/66/77
These M Codes are available in the machine side. The machine side inputs can be switched on by
transferring the output signal from Robot side to machine aide as a input signal.
The machine inputs can be switched on by transferring the high signal which comes from the Robot
side. The machine inputs can be switched off by transferring the low signal which comes from the Robot
side .
M70 X Mirror On
M70 sets X axis mirroring about the current X axis position.
M71 Y Mirror On
M71 sets Y axis mirroring about the current Y axis position.
M76/77 Wait for Auxiliary 1/2 on

M76 waits for auxiliary input 1 t become off
M77 waits for auxiliary input 2 to become off.
M80 X Mirror Off

M80 disables X axis mirroring
M81 Y Mirror Off

M81 disables Y axis mirroring
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M98 Subprogram Call

M98 causes another program to be executed. The "P" value specifies the program number and the
number of times to execute it.
The right most 4 digits are the program number.
The digits to the left are the number of repetitions.
There can be up to 999 repetitions, if the value is omitted it is called once.
Examples: M98 P12 and M98 P10012

Both execute CNC program 12 once.
M99 Subprogram Exit

Returns control to the program that called the current program.
If a "P" value is specified then execution begins form the block with the same "N" number, otherwise it
is form the block after the subprogram call.
If an M99 is specified in the main program then the execution is form the start of the program. This is
called looping (or) nesting of one or more programs
Example: M99
Returns to the block following the call.
M99 P10
Returns to the block with "N" value 10.
G CODES:
G Codes (Preparatory Functions) - Introduction.
Preparatory functions, called G codes, are used to determine the geometry of tool
movements and operating state of the machine controller; functions such as linear cutting
movements, drilling operations and specifying the units of measurement.
They are normally programmed at the start of a block.
A G code is defined using the following format:
G
where,
G is the address letter.
is the two digit number defining the G code.
G codes can be split into two categories1.
Modal (retained) G codes.

A modal G code, once programmed into a block, will affect any subsequent blocks of the
program without having to be restated.
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Additionally, modal G codes are further split into groups according to their task and
function. A modal G code will remain active until another G code from the same group is
programmed into a block, or it is cancelled.
For example,
G1 and G are modal G codes from group 1:
G1
X____;
Z____;
X____;
Z____;
2. Non-modal (one-shot) G codes.

A non-modal G code must be programmed into every block when it is required, ie, it is
only effective in the block in which it is specified.
List of G Codes:
G (Rapid Positioning / Traverse).
G1 (Linear Interpolation).
G2 / G3 (Circular Interpolation).
G4 (Dwell).
G2 / G21(Inch/Metric Data Input).
G28 (Reference Point Return).
G4 / G41 / G42 (Tool Nose Radius Compensation).
G5 (Multiple Command Functions).
G7 (Finishing Cycle).
G71 (Stock Removal in X Axis).
G72 (Stock Removal in Facing).
G73 (Pattern Repeating).
G74 (End Face Peck Drilling Cycle).
G75 (Outer / Internal Dia. Drilling & Grooving Cycle).
G76 (Multiple Thread Cutting Cycle).
G81 (Deep Hole Drilling Cycle).
G9 (Outer / Internal Dia. Cutting Cycle).
G92 (Thread Cutting Cycle).
G94 (End/Taper Face Turning Cycle).
G96 (Constant Surface Speed Control).
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G97 (Spindle Speed in Rev/Minute).

G98 (Per Minute Feed).
G99 (Per Revolution Feed).
G00 Rapid Traverse or fast Traverse

The G code executes a non cutting movement, at a rapid feedrate, to a specific coordinate position in the working area (absolute co-ordinate movement) or when a certain
distance from a previously stated
position (incremental co-ordinate movement) is
programmed.
AG00 causes the tool to move to the specified position at the maximum speed.
Example: G00 X20 Y30 Z1
Here the tool is moved to X 20mm, Y 30mm, and Z 1mm.
G01 Linear Interpolation or Slow Traverse

The example below shows a G1 command being used to produce both straight and
diagonal (vector) cutting moves. This can be achieved by programming the data using a
variety of methods.
AG01 causes linear motion to the given position.
Example : G01 X20 Y30 Z -1 F180
Here the tool is moved to X 20 mm, Y 30mm, and Z - 1mm at a feed rate of 180 mm per minute.
G02 Clockwise Circular Interpolation

Arcs can be specified by either radius or by centre.
If a positive radius is specified then the shorter arc is cut. If it is negative then the longer arc is cut.
When programming arcs, the end point of the arc is specified by the address X, Z when
stated as an absolute position, or U, W when stated as an incremental position. This arc
end point is sometimes referred to as the target position.
Using an absolute position (X, Z), the value is the dimension of the end point of the arc in
relation to the datum position of the component.
Using an incremental position (U, W), the co-ordinate of the end point is the distance the
tool moves from the start position of the arc. This can either be a plus (+) value or a
minus (-) value depending on the movement of the machine slides in relation to the start
position.
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Example: G02 X30 Y20 R15 F80

In this example the tool is moved to X30mm and Y 20mm. The arc has a radius of 15mm.
"I" and "J" specify the arc start. If the value is 0 then it need not be specified.
Example: G03 X30 Y20 I15 J0 F80
G03 Counter - Clockwise Circular Interpolation
G03 causes counter - clockwise circular motion.
Arcs can be specified by either radius or arc centre. If a positive radius is specified then the shorter arc
is cut. If it is negative then the longer arc is cut.
Example: G03 X30 Y20 R15 F80
In this example the tool is moved to X 30 mm and Y 20mm. The arc has a radius of 15mm
"I" and "J" specify the arc centre relative to the arc st art. If the value is 0 then it need not be specified.
G04 Dwell
A Dwell of up to 500 seconds can be programmed.
Example: G04 X10
This causes a delay in machining of 10 seconds. This can be used for drilling cycles.
G20 Imperial Units

All future instruction parameters will be taken as imperial values. That is, they will specify inches.
G21 Metric Units

All future instruction parameters will be taken as metric values. That is, they will specify millimeters.
By default metric units will be taken for part programming.
G28 Goto Reference Point

A G28 causes a fast traverse to the specified position and then to the machine datum.
Example: G28 X84.0 Y80.0 Z5.0
G40 Cancel Tool Radius Compensation

G40 switches off any tool radius compensation activated by a G41 or G42..
G41 Left Hand Radius Compensation

G41 causes future movement to take place to the left of the programmed path.
The offset used is equal to the radius of the current tool.
G42 Right Hand Radius Compensation

G42 causes future movement to take place to the right of the programmed path
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The offset used is equal to the radius of the current tool.
G73 Past Peck Drilling Cycle

Example: G73 X1.0 Y1.0 Z-5.0 Q0.3 R1.0 K1 P500 F30
"X" and "Y" are the next position to drill at.
"Z" is the base of the hole
"Q" is the cut in value
"R" is the R point level
"K" is the number of repetitions it defaults to 1
"p" Dwelling time
"F" Feed rate
G74 Counter Tapping Cycle

Example: G74 X1.0 Y1.0 Z-6.0 R1.0 P750 F30
"X" and "Y" are the next position to drill at
"P" is 1000 times the delay in seconds
"K" is the number of repetitions it defaults to 1.
"F" Feed rate
G84 Tapping Cycle

Example : G84 X1.0 Y1.0 Z-6.0 R1.0 P750 K1 F30
"F" Feed rate
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G85 Boring Cycle

Example: G85 X1.0 Y1.0 Z-6.0 K1 F30
"F" Feed rate
G86 Boring Cycle

Example: G86 X1.0 Y1.0 Z-6.0 K1 F30
"F" Feed rate
G87 Back Boring Cycle

Example: G87 X1.0 Y1.0 Z-6.0 P300 Q0.7 K1 F30
"Q" is the shift value
"R" is the number of repetitions it defaults to 1
"F" Feed rate
G89 Boring Cycle

Example: G89 X1.0 Y1.0 Z-6.0 P1000 K1 F30
"F" Feed rate
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G90 Absolute Movement

All future movement will be absolute until over - ridden by a G91 instruction. This is the default setting.
Example: G90
G01 X30 Y0
The position becomes X30 Y0
G91 Incremental Movement

All future movement will be incremental until over - ridden by a G90 instruction.
Example: G90
G01 X15
G91
G01 X2
The position become X17
G92 Set Datum

G92 sets the datum relative to the current position.
Example: G00 X30.0 Y40.0

G92 X0.0 Y0.0
Makes the position that was X30 Y40 become X0 Y0
G94 Per Minute Feed

The "F" value specifies the feed rate in millimeters, or inches, per minute.
G95 Per Revolution Feed

The "F" value is the ratio of feed rate to spindle speed. The feed rate is changed whenever the spindle
changes.
Example: G95 S1200

G01 X10.0 P0.3
This sets the feed rate to 360, (1200*0.3)
G98 Initial Level Return

G98 sets the initial level return mode for drilling cycles.
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G99 R Point Return

G99 sets the R point return mode for drilling cycles.
Billet Definition
This directive allows the billet in the simulation window to be given a size
The billet definition should be placed at the start of a program, after the measure has optionally been
set.
Billets Definition
Example : G21
Sets the measure to metric
Billet X100.0 Y100.0 Z10.00
defines the billet as 100mm by100mm with a depth of10mm
Billet Edge Directive

This directive sets up the required offset from the program zero position to the left hand corner of the
billet. It is used by the on-screen simulation.
Example: G71
EDGEMOVE X0 Y-20
This example moves the billet corner by 0 mm on X and - 20 mm on Y.
Subprogram Directive
This directive allows a program with a non numeric name to be called as a subprogram.
Example: Subprogram 2 FRED

M98 P2
Clear Directive
This directive switches the tutorial messages windows.
Example: CLEAR
Step Directive
This directive switches over to single step execution on - screen and when linked to the Fanuc machine
Example: STEP
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Single step off Directive

This directive switches off single step execution on- screen and when linked to the Fanuc machine.
Example: NOSTEP
Enable Simulation
Show Directive
This directive allows the operations to be simulated.
Example: SHOW
Disable Simulation
This directive stops the operations being simulated.
Example: NOSHOW
Tutorial Message
Tutorial message instructions being with the "!" Exclamation mark which is followed by some text.
When the CNC program is executed your text will appe ar in the "Tutorial" window at the bottom of the
screen.
Example: !Using tool 2.

Tutorial pause.
Tutorial pause instructions begin with the "?" question mark which is followed by some text.
When the CNC program is executed your text will appe ar in the "Tutorial" window at the bottom of the
screen. You will then be prompted to press a key to continue.
Example: Check the position Directive.

There are a selection of Directives used within th e CNC program for controlling the simulation and the
manual control select one of them form the menu fore more information.
Tutorials
Interactive lessons can be developed through the Tutorials facility, messages and questions can be
embedded within the CNC program.
! Displays message without stopping

? Displays message but stops for key press.
Tool Definition Directive
This directive sets up the length and diameter of a tool.
The length is the distance from the spindle nose to the bottom of the cutter.
Example: G21
TOOLDEF T1 D8 Z65
This example define tool 1 as being 8mm in diameter, and 65mm long.
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Sample Programs
LINEAR INTERPOLATION
Figure : 9.1
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LINEAR INTERPOLATION
BILLET X100 Y100 Z10
EDGEMOVE X-50 Y-50
TOOLDEF T2 D6
N010 G21 G94
N020 G91 G28 Z0
N030 G28 X0 Y0
N040 M06 T2
N050 M03 S1200
N60 G90 G00 X-40 Y-40
N070 Z5
N080 G01 Z-1 F50
N090 Y40
N100 X40
N110 Y-40
N120 X-40
N130 X40 Y40
N140 G00 Z5
N150 G00 X-40 Y40
N160 G01 Z-1 F50
N170 X40 Y-40
N180 G00 Z5
N190 M05
N200 G91 G28 Z0
N210 G28 X0 Y0
N220 M30
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LINEAR WITH CIRCULAR INTERPOLATION
Figure : 9. 2
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LINEAR WITH CIRCULAR INTERPOLATION

EDGEMOVE X-50 Y-50
TOOLDEF T2 D6
N010 G21 G94
N020 G91 G28 Z0
N030 G28 X0 Y0
N040 M06 T2
N050 M03 S1200
N060 G90 G00 X-22.5 Y-37.5
N070 G00 Z5
N080 G01 Z-1 F50
N090 G03 X-37.5 Y-22.5 R15
N100 G01 Y22.5
N110 G03 X-22.5 Y37.5 R15
N120 G01 X22.5
N130 G02 X37.5 Y22.5 R15
N140 G01 Y-22.5
N150 G03 X22.5 Y-37.5 R15
N160 G01 X-22.5
N170 G00 Z5
N180 G00 X-15 Y0
N190 G01 Z-1 F50
N200 G03 X15 Y0 R15
N210 G03 X-15 Y0 R15
N220 G00 Z5
N230 M05
N240 G91 G28 Z0
N250 G28 X0 Y0
N260 M30
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XLMILL User Manual
Exersices
CREATING AN ARC
Figure : 9. 3
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Exersices
XLMILL User Manual
ARC EXPLANATION
EDGEMOVE X-10 Y-10
TOOLDEF T2 D6
N010 G21 G94
N020 G91 G28 Z0
N030 G28 X0 Y0
N040 M06 T2
N050 M03 S2500
N060 G90 G00 X10 Y10
N070 G00 Z5
N080 G01 Z-1.2 F50
N090 G02 X10 Y70 R100
N100 G02 X70 Y70 R100
N110 G02 X70 Y10 R100
N120 G03 X10 Y70 R30
N130 G03 X70 Y70 R30
N140 G03 X70 Y10 R30
N150 G03 X10 Y10 R30
N160 G00 Z5
N170 M05
N180 G91 G28 Z0
N190 G28 X0 Y0
N200 M30
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Exersices
XLMILL User Manual
MIRROR IMAGING
Figure : 9. 4
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Exersices
XLMILL User Manual
MIRROR IMAGING
BILLET X100 Y100 X10
EDGEMOVE X-50 Y-50
TOOLDEF T2 D6
N010 G21 G94
N020 G91 G28 Z0
N030 G28 X0 Y0
N040 M06 T2
N050 M03 S1800
N060 G90 G00 X0 Y0
N070 G00 Z5
N080 M98 P0010008
N090 M70
N100 M98 P0010008
N110 M80
N120 M70
N130 M71
N140 M98 P0010008
N150 M80
N160 M81
N170 M71
N180 M98 P0010008
N190 M81
N200 G00 Z5
N210 M05
N220 G91 G28 Z0
N230 G28 X0 Y0
N240 M30
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XLMILL User Manual
Exersices
PROFILE MILLING
Figure : 9. 5
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Exersices
XLMILL User Manual
SAMPLE PROFILE
EDGEMOVE X0 Y0
TOOLDEF T2 D6
N010 G21 G94
N020 G91 G28 Z0
N030 G28 X0 Y0
N040 M06 T2
N050 M03 S2000
N060 G90 G00 X5 Y42 Z5
N070 G01 Z-1 F50
N080 G03 X4 1 Y27 R43
N090 X64 Y31 R29
N100 G01 X62 Y35
N110 G03 X80 Y49 R32
N120 X93 Y56 R36
N130 G02 X76 Y76 R26
N140 X67 Y62 R30
N150 X59 Y70 R6
N160 G01 X41 Y76
N170 X35 Y69
N180 G03 X5 Y56 R43
N190 G02 X5 Y42 R8
N200 G01 Z5
N210 G00 X17 Y56
N220 G01 Z-1
N230 G01 Z5
N240 G91 G28 Z0
N250 G28 X0 Y0
N260 M05
N270 M30
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Maintenance Procedure
XLMILL User Manual
10. Maintenance Procedure:

While carrying out maintenance work, pay out special attention to the following items to
ensure safe and in correct procedure.
Before starting any maintenance work, define the task and obtain the information relavent to
carry out the maintenance. Defining the work period and to do the necessary work is as follows.
Main Maintenance:
Apply oil regularly in the machine for Proper Maintenance
Drain the FRL unit and compressor unit regularly.
After using the machine, clean the machine properly to avoid the dust particles which froms
an accuracy in the machine.
Allow to use work piece which is instructed by MTAB (Aluminum, Aerolic, Steel are work
pieces can be used.). Should not use the wood pieces it will spoil the machine.
Arrange for a compressor (min 100litres) in case of working with pnematic systems.
(appliable to milling machines and FMS)
Always switch on the machine using a Stabilizer.
Emergency Stop:
Emergency Stop is used to avoid the eradication during the processment of the machine. Sudden
stop of the machine. The user can use this emergency stop button only during the emergency
requirement period
Emergency Stop.
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Maintenance Procedure
XLMILL User Manual
The XLMILL inspection and maintenance must be carried out according to the following
schedule
PERIOD
Daily
MAINTENANCE REQUIRED
Lubricate the oil nipples
Clean the slides and coat with a thin

film oil
Weekly
Clean out the swarf
Clean the mill thoroughly
Check the screws and nuts for

tightness
Six Months
Lubricate both the ball screws
Check the adjustment of the saddle

and the cross slide strips
Annually
Grease the headstock bearing
Check the mill alignments and

accuracy
Call the service engineer to have a

complete check
General Maintenance:
Always switch on the machine using a Stabilizer .
Provide a proper secure place and dust free environment for installing the
machine.
Clean the machine after completion of the work.
Oil weekly. Lubrication at home position only.
Note:
Regular maintenance of the XLMILL increases its life and performance
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Trouble shooting
XLMILL User Manual
11. Trouble Shooting

1. Spindle is not running, even after switching ON the power supply
Check whether the devices are switched ON. Check the F1 fuse; also check whether the LED
for supply, trip and enable are glowing in green, red and green to identify existence of trip due to
over current
2. Unable to link the Machine.
Switch off the controller.Open the control box. Check the fuse F2 and F5 at the main fuse
bank. If the fuse seen blown, flow the fuse with the same value written on it.
3. Solution for the Multidimensional work piece to be processed in the XL Mill
Set multiple reference points so that the tool will correctly processes the work piece.
4. Suppose the XL Mill is not starting after switching ON the power supply.
Check whether the controller is properly connected.
5. This method should be followed when the head column is loosened
Adjust Gib strip so that the head column is tightened using the gib strip adjustment screw.
Also take care that the gib strip adjustment screw is not over tightened.
6. At which position the spindle should be rotated initially?
The Spindle should be rotated after the tool holder is moved is to home position, so as to
prevent the damage to the work piece.
7. If Machine shows time out error
Check the machine whether the communicaion cable is properly connected(USB) or used
cables.
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Trouble Shooting
XLMILL User Manual
CNC Machine XLMILL control side trouble Shooting:

Fuse Checking Procedure
Refer to the controller side layout provided and check the following Fuses F1 to F5 at the
main fuse bank as per the procedure in TABLE 1.
Table 1: XL MIL
Sl.No
Fuse
No(s).
Fuse F2,
F5
When to check?
1.Unable to link the
machine.
2.Denstep controller
is not switched on (.L
display is not coming)
Fuse F1
1. Spindle motor is not

functioning
Fuse F3
1.ATC motor is not

functioning
Fuse F4
1. Unable to execute
Homing
2. Control box fan and
the machine Work
light is not functioning.
How to check?
Switch off the
controller. Open the
control box, check the
fuse F2 and F5 at the
main fuse bank. If the
fuse seen blown,
replace the fuse with
the same value written
on it.
Switch off the
fuse F1 at the main
fuse bank. If the fuse
seen blown, replace
the fuse with the same
value written on it.
Switch off the
fuse F3 at the main
fuse bank. If the fuse
seen blown, replace
the fuse with the same
value written on it.
Switch off the
fuse F1 and F5 at the
main fuse bank. If the
fuse seen blown,
replace the fuse with
the same value written
on it.
Problem solved
yes/no
Yes/no
If no, please refer to
table 2, first row.
Yes/no
table 2, second row.
Yes/no
If no, consult for
servicin.
Yes/no
table 2, third row.
Refer the TABLE 2 for rectifying the problems that are answered No in Table 2
84 of 110
Trouble shooting
XLMILL User Manual
Before start working inside the control box.

please refer to control box layout.
For Reference
Sl.No
1
Problem Description
Remedial Action
1.Unable to link the machine.
Switch off the

controller .Open the
control box ,check the
fuse at the denstep
controller card.
Yes/no
Switch off the

two fuses at the
spindle drive card.
Switch off the
two fuses at the power
supply card.
Yes/no
2.Denstep controller card is not
switched on (.L display is not

coming.)
1.Spindle motor is not
functioning.
1. 24 V dc power supply is not

working.
Problem solved
Yes/no
If no, refer to the note
given below.
If no, consult for

servicing.
Yes/no
If no, consult for
servicing
Fuse F1 3.15 Amps

Fuse F2 6.3 Amps
Fuse F3 3.15 Amps
Fuse F4 3.15 Amps
Fuse F5 2 Amps
Denstep controller card fuse 3.15 Amps.
Spindle drive card two fuses are of same rating 2 Amps.
85 of 110
Overall Layout of the machine
XLMILL User Manual
12. Overall Layout of the Machine
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Electrical Drawings
XLMILL User Manual
13. Electrical Drawing
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Electrical Drawings
XLMILL User Manual
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Electrical Drawings
XLMILL User Manual
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Electrical Drawings
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Electrical Drawings
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Electrical Drawings
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Electrical Drawings
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Electrical Drawings
XLMILL User Manual
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Glossary
XLMILL User Manual
14. Appendix
Glossary
ATC (Automatic Tool Changer):
Automatic Tool Changer is an automated tool changer equipment that helps in changing the tool automatically. - - - 6
Boring:
Boring is the operation of enlarging and truing a hole produced
by drilling, punching. - - - - - - - - - - - - - - - - - - - - - - 1
Computer Numerical Control
CNC allows the control of motion in an accurate and programmable manner through the use of a dedicated computer. 1
Chamfering
Operation of bevelling the extreme end of the work piece. 1
Drilling:
Drilling is the operation of producing a cylindrical hole in a
workpiece by rotating cutting edge. - - - - - - - - - - - - - 1
Milling
Milling is the operation of removing metal by feeding the work
against a rotating cutter having multiple cutting edges. 1
Pocketing
Pocketing is the process of creating pockets over a work piece
surface. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
Grooving It is a process of reducing the diameterof a work piece over a
very narrow surface. - - - - - - - - - - - - - - - - - - - - - - - 1
JOG :
Shake with the push or jerk, and moves up or down with an unstead motion. - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18
Threading
Operation of producing helical groove on a cylindrical or conical
surface. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
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Glossary
XLMILL User Manual
Parting
Operation of cutting a work piece after it has been machined to
the desired size and shape. - - - - - - - - - - - - - - - - - - - 1
Pull stud
Pull stud is used to Clamp the tool holder firmly in the machine
head. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6
Pneumatic Intensifier:
This further intensifies the pneumatic pressure - - - - - 6
Roughing
Process of removal of exess material from the work piece in a
minimum time by applying high rate of feed and heavy depth of
cut. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
Reaming
It is a Multi-tooth cutter which removes relatively small amount
of material. - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
TappingOperation of cutting internal threads of small diameters using a
multipoint cutting tool called Tap. - - - - - - - - - - - - - - 1
Stabilizer
A device that produces a stabilized power output without any
fluctuations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 16
102 of 110
Index
XLMILL User Manual
Index
A
Add a Tool .......................................................................50
ATC (Automatic Tool Changer .......................................6
Allen Key ........................................................................3
Air Filter Regulator .........................................................12
Anti-clockwise ................................................................12
Automatically ..................................................................49
B
Billets ..............................................................................3
Billet Length ...................................................................47
Billet Width .....................................................................47
Billet Depth .....................................................................47
C
CNC Machine XLMILL control side trouble Shooting ..67
Clamping Kit ...................................................................2
Com Port Options ...........................................................51
D
DRAIN ............................................................................12
Datum ..............................................................................62
Datam Plate and Billet Clamp ........................................3
Double Ended Spanner ...................................................3
Delete a Tool ...................................................................50
E&F
Editor ..............................................................................42
Fanuc Emulated Control Programming Software ...........1
H
High visibility guard .......................................................1
Hydro Pneumatic Vice ....................................................5
Hydro Pneumatic Pressure Intensfier .............................5
Hydro pneumatic vice caring ..........................................5
Hydro Pneumatic Vice ....................................................6
L
Lubricator ........................................................................12
Load Work shift offsets ...................................................46
103 of 110
Index
XLMILL User Manual
M
Manufactured ..................................................................1
Machine Installation .......................................................8
Machine ..........................................................................43
Machine Settings .............................................................43
Machine File Name .........................................................45
Machine Link option .......................................................54
Machine Control Settings ...............................................50
MDI Panel .......................................................................53
O
Optional Equipments ......................................................2
Offset ...............................................................................46
Oilcan with oil ................................................................3
P&R
Pneumatic System ...........................................................12
Parameter settings ...........................................................44
Requirements for Machine Connection ..........................15
Running the Machine ......................................................57
Relevant column .............................................................48
S
Saftey Precautions ...........................................................65
Save Workshift Offsets ...................................................46
Safety Regulations ..........................................................8
Set ...................................................................................42
Simulation purpose only .................................................47
Screwdriver set ...............................................................3
Setting the tool and billet ................................................55
Simulation .......................................................................56
T&U
TOOL LENGTH .............................................................48
.Taking Tool Offset and Work Offset ..............................57
Trouble Shooting .............................................................66
Use to hold the tools in the Automatic Tool Changer ...7
UpLifting of XL Mill ......................................................8
104 of 110

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ABOUT THE MANUAL

MTAB ENGINEERS (P) LTD.

4. Structure and specifications: . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

6. CNC TRAIN Installation procedure . . . . . . . . . . . . . . . . . . . . .19

10. Maintenance Procedure: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

12. Control Panel Layout . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . 86

XLMILL User Manual

Check the status of slideway lubrication daily

Safety Operation Procedure:

XLMILL User Manual

Common Safety Precautions:

Introduction and Description

XLMILL User Manual

2. Introduction of the Machine

Front View of XLMILL

Features of the XLMILL

Introduction and Description

XLMILL User Manual

Description of XLMILL Machine

XLMILL User Manual

3. Description of XLMILL Machine

i. Hydro Pneumatic Pressure Intensifier with Single Acting Cylinder

Description of XLMILL Machine

XLMILL User Manual

ii. Hydro Pneumatic Vice:

ATC (Automatic Tool Changer)

Description of XL MILL Machine

XLMILL User Manual

Tool Holder is used to hold the tool

Operating Procedure for non ATC Machines:

Lever with Key

Description of XLMILL Machine

XLMILL User Manual

Description of XLMILL Machine

XLMILL User Manual

Description of XLMill Machine

XLMILL User Manual

Back view of XLMILL

Air Filter Regulator and Lubricator

Description of XLMILL Machine

XLMILL User Manual

The air Lubricator Oil - (Suitable)

Layout for Back View of XLMILL ATC

Structure and specification

XLMILL User Manual

4. Structure and Specifications:

Full View of Machine Dimension

Inner view of Machine Dimensions

Structure and Specifications

XLMILL User Manual

Lengthwise Dimension 575MM.

Structure and Specifications

XLMILL User Manual

Spindle Travel Over Table

XLMILL User Manual

Structure and specification

Spindle to table Distance

Spindle Nose Taper

ATC - Maximum tool diameter

ATC Maximum tool length

Programmable Spindle Speed

150 4000 rpm

Table 2: Machine Specification

Programmable Feed Rate