Router SG

CNC Router
CNC Technology: Benchtop CNC Router
Student Activities Book
CNC Router
Student Activities Book
1997 Light Machines Corporation and Intelitek
Manchester, NH, U.S.A.
December, 1997 34-7535-0000
1997 Light Machines Corporation All Rights Reserved.

The information contained in this guide was accurate at the time of its printing. Light Machines Corporation reserves the right to change specifications and operational performance of its products without notice. Any changes or corrections to the information contained in this publication will be incorporated in future issues. This publication (34-7535-0000, December, 1997) corresponds to the Benchtop Router and LMR-8800 Control Program packages.
Printed in U.S.A.
BenchRouter and LMR8800 are trademarks of Light Machines Corporation. All other register marks or trademarks are of their respective holders.
WARNING
The operation of rotating machinery should only be attempted by experienced, knowledgeable individuals! Read the entire contents of the Safety Section before running NC programs on the Router. To avoid possible injury always observe the safety precautions described in this Guide.
Table Of Contents
Activity 1
Getting Started
Objectives ............................................................................................................ 1-1 Skills ..................................................................................................................... 1-1 Materials............................................................................................................... 1-1 Overview .............................................................................................................. 1-2 Safety Checklist.............................................................................................. 1-5 Lista de Seguridad .......................................................................................... 1-6 Emergency Stops ............................................................................................ 1-7 Procedures ............................................................................................................ 1-8
Activity 2
Router Components
Objectives ............................................................................................................ 2-1 Skills ..................................................................................................................... 2-1 Materials............................................................................................................... 2-1 Overview What is a CNC Router? ....................................................................... 2-2 Machine Components .................................................................................... 2-3 The Controller Box ........................................................................................ 2-4 X, Y, and Z Axes ........................................................................................... 2-5 Procedures ............................................................................................................ 2-6 Academics Vocabulary and Definitions .............................................................. 2-8
Activity 3
The Control Program

Objectives ............................................................................................................ 3-1 Skills ..................................................................................................................... 3-1 Materials............................................................................................................... 3-1 Overview What is a Control Program?................................................................ 3-2 Procedures ............................................................................................................ 3-2 Exploring the Control Program Screen ............................................................... 3-3
Student Activities Book 9712
Activity 4
Mounting the Stock

Objectives ............................................................................................................ 4-1 Skills ..................................................................................................................... 4-1 Materials............................................................................................................... 4-1 Overview .............................................................................................................. 4-2 Procedures ............................................................................................................ 4-2
Activity 5
Tooling
Activity 6
Home Positions
Objectives ............................................................................................................ 6-1 Skills ..................................................................................................................... 6-1 Materials............................................................................................................... 6-1 Overview .............................................................................................................. 6-2 Procedures ............................................................................................................ 6-2 Understanding Coordinate Systems ..................................................................... 6-4
Activity 7
Selecting an NC Program
Activity 8
Verify and Dry Run the Program

Student Activites Book 9712
ii
Activity 9
Run the NC Program

Activity 10
NC Programming
Objectives ........................................................................................................... 10-1 Skills .................................................................................................................... 10-1 Materials.............................................................................................................. 10-1 Overview What is NC Programming? ................................................................ 10-2 Elements of a Part Program ................................................................................ 10-2 Programming Suggestions .................................................................................. 10-5
Activity 11
Coordinate Systems
Objectives ........................................................................................................... 11-1 Skills .................................................................................................................... 11-1 Materials.............................................................................................................. 11-1 Overview Part 1 Coordinate Measurement ........................................................ 11-2 Two-Dimensional Measurement ........................................................................ 11-3 Three-Dimensional Measurement ...................................................................... 11-5 The Right-Hand Rule .......................................................................................... 11-5 Part 2 How Coordinates Relate to the Benchtop Router .................................... 11-6 Absolute and Incremental Programming ............................................................ 11-7 Interpolation ........................................................................................................ 11-9 Academics Vocabulary ..................................................................................... 11-12
Activity 12
Developing an NC Program
Objectives ........................................................................................................... 12-1 Skills .................................................................................................................... 12-1 Materials.............................................................................................................. 12-1 Overview ............................................................................................................. 12-2 Procedures ........................................................................................................... 12-2 Create Your Own NC Program .......................................................................... 12-9
iii
Activity 13
Editing Your NC Program

Objectives ........................................................................................................... 13-1 Skills .................................................................................................................... 13-1 Materials.............................................................................................................. 13-1 Overview ............................................................................................................. 13-2 Procedures ........................................................................................................... 13-2
Activity 14
Verify and Run Your Program

Activity 15
Conclusion
iv
About the Teklink Activities Book

The Teklink Activities Book is a lab manual which contains 15 Activities, each of which can be completed in one 45-minute lab session. Each activity begins with several lists: w w w Objectives are the goals students will achieve. SCANS Skills are the competencies students will develop. Materials are the specific items needed for each activity.
The Overview section introduces the students to the subjects which will be explored in each activity. The Procedures contain series of Tasks, or operations. The first time an operation is to be performed, instructions are given in a tutorial manner. In subsequent tasks students should be able to perform these operations without guidance. Questions and tables for entering lab results appear within the tasks. Questions for discussion and review conclude each activity. All questions and tables are printed on a set of Worksheets supplied with this book. Students should record their answers on the worksheets, or as directed by the instructor. The Academics section at the end of some activities contains enrichment material, such as industrial applications and opportunities, or the scientific background upon which the Teklink is based. In activities which include hardware (e.g., vise, tooling), students will be directed to perform inventory and safety checks at the beginning of every working session, and to shut down the system properly at the end of each activity. In activities which utilize software, it is assumed that students are familiar with the PC and are comfortable working in the Windows/DOS operating environment. However, instructions for operating the software are explicit and can be performed by novices.
vi
Activity 1
Getting Started
SAFETY RULES Safety is a very important issue in a machining environment. You hear stories all the time about the dangers of operating machinery. People getting their hair caught in rotating machines, students and teachers not paying attention to their work and cutting off fingers; some are life threatening injuries, others, at the least are permanently damaging. We require that you read and understand all of the following safety rules, that you pass, with a score of 100%, a written test on these rules, and sign the test stating you will follow these guidelines every time you operate the machine. Safety is not to be taken lightly! We have included a Safety Checklist that should be copied and posted next to the router. It must be completed by the machine operators every time the machine is run. In the activites you will be instructed to complete this checklist at the beginning of the tasks. OBJECTIVES In this activity you will accomplish the following: w w SKILLS In this activity you will develop the following skills: w w w w w MATERIALS In this activity you will need the following materials: w Answer Sheet for the Safety Test Resources: Information: Basic: Thinking: Personal: Manage time Acquire / evaluate information Reading and writing Learning Responsibility and self-management Learn all of the Safety Rules for operating the Router Pass, with a score of 100%, the test on the Safety Rules
1-1
OVERVIEW The following is the list of the Safety Rules for operating the Router. Read through them until you are familiar with them. When everyone has finished, your instructor will give you the test. You must pass with a perfect score. WEAR S AFETY G LASSES Foresight is better than no sight. During operation, any power tool can throw foreign objects and harmful chemicals into your eyes. Always put on safety glasses or eye shields before starting up the router. Safety glasses or shields should provide full protection at the sides, as well as the front of the eyes. KNOW Y OUR MACHINE TOOL Read this guide carefully before you use the router and keep it readily accessible for quick reference. Know the intended applications and limitations of the router as well as its hazards. GROUND ALL TOOLS The router has an AC power cord terminated by a three-prong plug. The power cord should be plugged into a three-hole, grounded receptacle. If a grounding adapter is used to accommodate a two-prong receptacle, the adapter wire must be attached to a known ground. Never remove the third prong from the plug on the AC power cord. KEEP THE SAFETY SHIELD IN PLACE The safety shield should remain in place whenever the spindle motor is on or the cross slide is moving. REMOVE ADJUSTING KEYS AND WRENCHES Make it a habit to check that keys and adjusting wrenches are removed from the router before turning on the machine. KEEP THE W ORK AREA C LEAN Cluttered work areas and bench tops invite accidents. AVOID A DANGEROUS ENVIRONMENT Dont use the router in damp or wet locations. Never operate electrical equipment in the presence of volatile and flammable petroleum-based solvents and lubricants.
1-2
KEEP UNTRAINED VISITORS AWAY FROM THE EQUIPMENT Children, and visitors unfamiliar with the hazards of rotating machinery should always be kept away from the work area. PREVENT UNAUTHORIZED USERS FROM OPERATING THE ROUTER Lock and remove the key from the router control panel when the system is not in use. DO NOT FORCE A TOOL Select the feed rate and depth of cut best suited to the design, construction and purpose of the cutting tool. It is always better to take too light a cut than too heavy a cut. USE THE RIGHT TOOL Select the type of cutting tool best suited to the operation. Don't force a tool or attachment to do a job it wasn't designed to do. DRESS APPROPRIATELY Don't wear loose clothing or jewelry which can get caught in moving parts. Wear a hat or hairnet, or tie your hair back to keep it away from moving parts. SECURE THE WORKPIECE Be certain that you have firmly secured the workpiece and the cutting tool in the collet before turning on the spindle motor. DO NOT OVERREACH Keep your footing and balance at all times so you wont fall into or grab the moving machine. MAINTAIN CUTTING TOOLS IN TOP CONDITION Keep cutting tools sharp and clean. Lubricate and clean router components on a regular basis. DISCONNECT TOOLS BEFORE SERVICING Always use the emergency stop switch to disconnect power and disable the spindle motor before mounting or removing the workpiece, or changing tools. Do not rely solely on a programmed Pause command to disable router operation.
1-3
AVOID ACCIDENTAL STARTING Make sure the power switch on the router is off before plugging in the power cord. USE RECOMMENDED ACCESSORIES To avoid stressing the router and creating a hazardous machining environment, use only those accessories designed for use with the router, available through Light Machines Corporation. TIGHTEN ALL HOLDING, LOCKING AND DRIVING DEVICES Tighten the collet. Do not overtighten tool holding devices. Overtightening may damage threads or warp parts, thereby reducing accuracy and effectiveness. DO NOT OPERATE THE MACHINE UNDER THE INFLUENCE
OF
ALCOHOL OR DRUGS
Alcohol or drugs may impair your judgement and reaction time, which could contribute to an on-the-job accident. AVOID DISTRACTIONS WHILE RUNNING THE MACHINE Use simple common sense and pay attention while operating any piece of machinery.
1-4
Safety Checklist
Before you enter the work area: q q q q q q q q q q q q Put on safety glasses. Tie back loose hair and clothing. Remove jewelry including rings, bracelets and wristwatches.
Before machining a part: Make sure you have the correct tool for the job. Secure the tool properly. Make sure all tool positions have been properly initialized. Verify the NC program on the computer before machining. Remove all loose parts and pieces from the machine. Remove adjusting keys and wrenches from the machine. Close the safety shield. Only operate the machine after being properly trained in its use. Perform a dry run: q q q q q Set the spindle speed to lowest manual speed setting. Make certain there is no workpiece in place. Run the NC program to make sure all the moves make sense before running the program with a workpiece in place.
After completing the dry run, properly secure the workpiece to the machine. Keep fluids away from all electrical connections, electronic or electrical devices, the computer and nearby electrical outlets.
While machining a part: q q q q q q Do not touch moving or rotating parts. Press the Emergency Stop button before opening the safety shield. Only open the safety shield after the spindle has stopped rotating. Press the Emergency Stop button whenever changing tools or mounting or removing a workpiece. Pull the Emergency Stop button out only after closing the safety shield. Keep all unauthorized persons away from the work area.
1-5
Lista de Seguridad
Antes de entrar en el rea de trabajo: q q q q q q q q q q q Use sus lentes de seguridad. Procure recogerse el cabello y no usar ropa floja. No use joyera como: anillos, pulseras y relojes.
Antes de trabajar a mquina una pieza: Utilize la herramienta correcta para el trabajo. Asegurela de forma correcta en el husillo con una boquilla. Asegurese que la posicin de la herramienta de corte ha sido inicializada correctamente. Remueva todas las partes sueltas y coloquelas lejos de la Fresadora. Limpie todos los residuos de la Fresadora despus de cada corrida. Cierre la guarda de seguridad antes de ejecutar cualquier operacin en la Fresadora. Corra los programas por primera vez con el motor del husillo apagado y sin pieza de trabajo. Asegurese que todos los movimientos sean correctos. Asegure la pieza de trabjo a la mesa. Quite las herramientas y llaves antes de cerrar la guarda de seguridad. Asegurese que todos los contactos de corriente A.C. esten aterrizados. Mantenga los lquidos refrigerantes lejos de la Caja de Control, Computadora y cualquier Suministro Elctrico.
Mientras trabaja a mquina una pieza: q Nunca levante la guarda de seguridad mientras que la Computadora este ejecutando un programa. Presione siempre primero el botn de Paro de Emergencia. Presione siempre el botn de Paro de Emergencia cuando se cambie una herramienta, se coloque o remueva una pieza de trabajo. Jale el botn de Paro de Emergencia despus de haber puesto la guarda de seguridad. Mantenga fuera del rea de trabjo a toda persona no autorizada.
1-6
Emergency Stops
All operators must be aware of how to shut down the machine quickly, should the need arise. In an emergency, always use the red Emergency Stop button on the machine front panel. You can also stop the machine by pressing the Control and Space keys on the computer keyboard, or by clicking on the stop buttons on the screen with the mouse. But, in an emergency, always use the Emergency Stop button on the machine.
Emergency Stop Button
1-7
PROCEDURES
Task 1-1 Safety Test

When using the Router, are the following practices safe or unsafe? Write S (safe) or U (unsafe) on the line next to each statement. ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ ______ Wear safety glasses while operating the Router. Roll your sleeves up above the wrists. Wear a loose chain around your neck while you operate the Router. Leave a wrench in the work area so you can use it later, and turn on the Router. Verify your part programs before actually running them on the Router. Raise the safety shield while the Router is operating. Plug the Router into a two-prong extension cord. Use a brush to remove chips while the Router is operating. Follow the safety rules every time you operate the Router. Wear a loose, unbuttoned shirt when operating the Router. Make sure the cutter is securely mounted to the spindle. Make adjustments while the Router is operating. Turn on the Router when it is sitting on a damp surface. Turn on the Router before your instructor checks the setup.
I have answered all of the safety questions correctly and understand every one of the safe practices explained in this lesson. I agree to follow these practices every time I work with the Router.
Student:
Date:
Instructor:
Date:
1-8
Activity 2
Router Components
Before you begin this activity, make sure you have completed the Safety Section and passed the written test. You must answer all the questions correctly to pass. When you have completed the Safety test you may begin this activity. OBJECTIVES In this activity you will accomplish the following: w w SKILLS In this activity you will develop the following skills: w w w w w w w w MATERIALS In this activity you will need the following materials: w w w Benchtop CNC Router Computer with the BenchRouter Control Program installed Worksheets for Activity Two Technology: Systems: Resources: Interpersonal: Information: Basic: Thinking: Personal: Maintain equipment Understand a system Manage time Participate as a member of a team Acquire / evaluate information Reading and writing Learning Responsibility and self-management Measure your knowledge of machining Identify the router hardware components
2-1
OVERVIEW
WHAT IS A CNC ROUTER? A router is a machine that uses a cutting tool, or router bit, to remove material from a workpiece to create a part. The router bit is mounted in the spindle, and rotates at a high speed. The spindle head moves up and down, front to back, and side to side. All these movements are coordinated by a computer to create a finished part. The CNC Router is a router which is controlled by a computer. The system has three components; the CNC Router, the controller box, which is mounted on the back of the router, and the computer which runs the control program software. CNC stands for Computer Numeric Control, and describes how the computer tells the router to move while cutting the stock. In other words, the computer is controlling the motions of the router by numeric code. The process works like this; a trained operator affixes a workpiece to the hold down table and a router bit into the spindle. Then an NC program is loaded into the computer. This program controls the speed of the spindle as well as the movements of the spindle head, so that neither the tool or the machine is overloaded. These motions result in the cutting tool being brought into contact with the workpiece, and removing material from the workpiece. CNC machines are used widely today in all types of industry. Machine shops that specialize in tool making and die cutting use mills and lathes. But CNC machine tools are also found in many Research and Development departments of just about any company. The reason is simple. CNC tools allow you to create a working prototype of a product or an idea. By simply having a physical three dimensional example of your idea, it becomes much easier to understand the concept, to improve on the design, and to generate interest in the idea. It makes it easier to sell the idea to potential customers or financial backers when you can hand them a model of what the product will look like. And in short run production, it keeps the costs down by allowing you to produce the part in house rather than having to send it out to be machined. Lets take a look at the major components of the Router. As you read through the descriptions, review the diagrams and locate the components on your lab machine.
2-2
MACHINE COMPONENTS The CNC Benchtop Router components are mounted inside an enclosure (1). The enclosure has a safety shield (2). The safety shield helps protect you from flying chips of material. The safety shield must be closed at all times when the Router is operating. The Router has a spindle which holds the cutting tool, or router bit. The bit is mounted in a collet or other tool holding device. The spindle motor (3) rotates the spindle and the cutter. The workpiece is held in place by hold-down clamps. The Router has three stepper motors. These motors control the movement of the spindle head. The Z axis stepper motor (4) moves the spindle head up and down; into and out of the workpiece. The X axis stepper motor moves the spindle head to the left and right. The Y axis stepper motor moves the spindle head toward or away from the back of the machine. The Router has two controls mounted on the front panel. The spindle speed control switch (5) controls the speed of the spindle motor. The available speeds range from 10,000 to 25,000 revolutions per minute (RPM). The spindle speed can be controlled manually or by computer. The emergency stop button (6) halts all Router operation when it is pressed. To resume operation, make sure the safety shield is closed, twist and release the button.
Z Axis Stepper Motor Emergency Stop Button
Spindle Motor
Spindle Speed Control
Safety Shield
Enclosure
2-3
THE CONTROLLER BOX The Controller Box houses the power- and interface-related controls for the machine. The Power Switch and Key Lock Switch are on the front panel of the box. The Key Lock switch keeps unauthorized persons from turning on the machine. Once the Key Lock is in the unlocked position, the Power switch can be turned on. The Power switch lights up when power is turned on. The rear panel houses the power and interface connectors and the fuses. The machine has five fuses for main power, the spindle, the stepper motors, and the two accessory outlets (labeled ACC 1 and ACC 2). The interface connectors are used to interface the Controller Box with the Router and the computer.
MOTOR DRIVES
usfe
use
MAIN
usfe
use
3A ACC 2
usfe
use
12A ACC 1
usfe
use
ONLY OPERATE WITH ALL CABLING SECURELY FASTENED BETWEEN THE MACHINE TOOL AND THIS BOX
120VAC, 5A
WARNING! DO NOT OPEN NO USER SERVICEABLE PARTS INSIDE

120VAC, 3A
usfe
3A
3A
5A
120VAC, 3A 120VAC, 60Hz, 15A
COMPUTER
TTL I/O
A & B AXES
2-4
se f
se f
fu
fu
se f
se f
SPINDLE
use
SPINDLE
ACC2
fu
fu
fu
se f
C AXIS
ACC1
X, Y, AND Z AXES Motion on the router is performed in 3 directions, or axes. All motion is relative to the workpiece. Movement from left to right or right to left is considered motion on the X axis. Moving to the right is positive motion, while movement to the left is in the negative direction. Moving from the front of the machine to the back is movement along the Y axis. If you are standing in front of the router, moving the spindle toward the back of the machine is positive motion, and moving it toward the front is, you guessed it, negative motion. It would only make sense then that the up and down motion is along the Z axis. Positive Z motion is up, while negative motion is down into the workpiece.
2-5
PROCEDURES
Task 2-1 Inventory and Safety Checks

w w w Q Q Check whether all materials required for this activity are available at your lab station. Verify that your lab station passes all the safety guidelines. Complete the inventory and safety checklists on the worksheet for this activity. What are 6 things you do not do while machining a part? Why should items like wrenches and keys be removed from the enclosure before operating the router?
Task 2-2 Identify Router Components

Q Q Q Q Q What is a CNC Router? Using your worksheet, fill in the names of the components indicated below. What is the purpose of the Safety Shield, and when is it used? What control on the router should you use in an emergency? What part of the router rotates the tool?
Emergency Stop Button
Enclosure
2-6
Task 2-3 Axes Identification

Q Using the worksheet, draw and label the 3 axes, and the positive and negative directions on each.
What parts of the Router do the X axis, Y axis and Z axis stepper motors move?
Task 2-4 Controller Components

Q Q Q Where is the controller power on/off switch located? Where is the controller fuse panel located? What does the Controller Box do?
Task 2-6 Discussion and Review

Q Q What have you learned about routers and CNC Machines in general? About Safety? List 3 things that you think are important to know when using the Router.
2-7
Task 2-7 Inventory and Shut Down

w w w w w w ACADEMICS Return all materials to their proper place at your lab station. Complete the Inventory Checklist for your station. Select Exit from the File menu to exit the control program. Shut off the router and the controller box. Select Shut Down from the Start menu on the computer. Shut the computer off.
VOCABULARY AND DEFINITIONS Control Program - The software program that controls the Router. Controller Box - The unit that houses the electronics to interpret part programs and sends them to the Router. Cutter (or bit) - A cutting tool. Emergency Stop Button - A control that can immediately shut-down all Router operations. Enclosure - The cabinet that houses the Router. Safety Shield - The clear cover of the Router enclosure. Spindle - The component of the Router that rotates the router bit. Spindle Motor - The motor that drives the spindle and rotates the router bit. Spindle Shaft - The portion of the spindle assembly to which the bit is secured. Spindle Speed Control Switch - The switch that controls the rate the spindle turns in revolutions per minute (RPM). X Axis Stepper Motor - The motor that controls the left and right movement of the spindle head. Y Axis Stepper Motor - The motor that controls the movement of the spindle head from front to back of the machine. Z Axis Stepper Motor - The motor that controls the up and down movement of the spindle.
2-8
Activity 3
The Control Program

OBJECTIVES In this activity you will w w w w w w SKILLS In this activity you will develop the following skills: w w w w w w w w MATERIALS You will need the following materials for this activity: w w w w This Guide The Benchtop Router Computer and mouse Control Program loaded onto the computer Technology: Systems: Resources: Interpersonal: Information: Basic: Thinking: Personal: Use and Maintain equipment and computer programs Operate the machining system Manage time Participate as a member of a team Acquire / evaluate information Reading and writing Learning Responsibility and self-management Start the computer Turn on the Controller Box and Benchtop Router Start the Control Program Maneuver through the control program screens Operate various inputs and outputs Jog the X, Y, and Z axes
3-1
OVER VIEW
WHAT IS A CONTROL PROGRAM? The BenchRouter Control Program is the computer program that helps you to operate the machine. It is designed so you can easily operate all the functions of the router. By using the computer, mouse, and keyboard, you can set operating parameters, verify, edit, run an NC program, and machine a part. The control program is a graphical interface that allows you to operate all phases of the machine. There are different screens, windows and buttons that make up the control program. Each serves a different purpose, and is explained as you go through this activity. In this section you will learn to start the computer, controller box and machine, start the control program, open and close windows, activate the machine by using different functions and buttons, and shut down all the parts of the Benchtop Router.
PROCEDURES
Task 3-1 Inventory and Safety Check

w w w Check that all materials required for this activity are available at your lab station. Verify that your lab station passes all the safety guidelines. Complete the inventory and safety checklists on the worksheet for this activity.
Task 3-2 Start the Control Program

To start the Control Program: w w w w w w Power up the computer (always do this first). Switch on the Controller Box. Release the Emergency Stop Button if it is not already pulled out.
From Windows 95: When the Windows desktop appears, select Start from the Task Bar. From the Start menu, select Programs and then the BenchRouter folder. In that folder, select BenchRouter .
From Windows NT double-click the BenchRouter icon in the BenchRouter Group.
3-2
EXPLORING THE CONTROL PROGRAM SCREEN You should become familiar with the main parts of the Control Program screen before you begin using the Control Program to run NC part programs. The following are the default components that make up the screen.
Menu Bar Title Bar Message Bar Position Readout
Standard Tool Bar
Outputs Tool Bar Edit Window Machine Info Panel Inputs Tool Bar
Verify Window
Status Bar
Task 3-3 Menu Bar

The Menu Bar contains all of the menu commands for the Control Program. w w Move the mouse over the Menu bar on your computer screen. Click on each of the menu items and observe the drop down menus
Task 3-4 Standard Tool Bar

The Standard Tool Bar provides easy access to many of the most often used commands. w w Read through the following descriptions of each button. As you read the explanations, find and select each item on your computer screen.
3-3
Tool
Function
New File
Begin a new NC part program file.
Open File
Open an existing NC part program file.
Save File
Save current NC part program file to disk or drive.
Cut NC Code
Cut selected code from program and place on clipboard.
Copy NC Code
Copy selected code to clipboard.
Paste NC Code
Paste code from clipboard to cursor position in program.
Print File
Send program to printer.
Help
Access Help program.
Context Help
Obtain help on selected object.
Jog Control
Access Jog Control Panel.
Operator Panel
Access Operator Control Panel.
3-D Verification
Access 3-D tool path verification.
Run (green)
Run the current NC part program.
Pause (yellow)
Pause the currently running NC part program.
Stop (red)
Halt the currently running NC part program.
Q
There are 3 ways to save an NC program. List 2 of them.

3-4 CNC Technology: Benchtop CNC Router
Task 3-5 Outputs Tool Bar

The Outputs Tool Bar is an active tool bar. The buttons act as switches, supplying power to the spindle and the Accessory outlets on the Controller Box. Switches for robotic outputs 1 and 2 are also provided. Power is on when the buttons are depressed. w Tool Move the mouse over each button and actuate and de-actuate the feature. Function
Spindle
Provides power to the spindle.
Acc1
Provides power to the Acc1 outlet on the Controller Box
Acc2
Provides power to the Acc2 outlet on the Controller Box
Robot 1
Provides power to the connector on the Controller Box for Robotic Output 1
Robot 2
Provides power to the connector on the Controller Box for Robotic Output 2
3-5
Task 3-6 Inputs Tool Bar

The Inputs Tool Bar is an inactive tool bar. It provides information only about the state of the switches. In other words, you cannot activate and deactivate features like you can with the Outputs tool bar. An input is active (on) when the button is depressed. w Q Click the mouse on each button. What happens different from when you did this exercise with the outputs toolbar? Function
Tool
E-Stop
Indicates when the Emergency Stop is pressed.
Safety Shield
Indicates when the Safety Shield is open.
Positive Limit
Indicates when the Positive Limit switch is on.
Negative Limit
Indicates when the Negative Limit switch is on.
Robot 1 Input
Indicates when Robotic Input 1
Robot 2 Input
Indicates when Robotic Input 2 is on.
3-6
Task 3-7 Edit Window

Whenever you open an NC part program file it appears in its own edit window. Edit windows have the same characteristics as other Windows 95 windows (scroll bars, minimize/maximize buttons, etc.). You can have as many edit windows open at a time as the computer memory will allow. In other words, when you crash the system, its too many. By default, each new window is locked; you can not edit a locked window. To unlock the window, use the Lock command under the Edit Menu. w Resize this window by clicking one of two size buttons at the right end of the Title bar.
Here is what the edit window for an NC part program titled Domino.NC looks like.
3-7
Task 3-8 Status Bar

The left side of the Status Bar provides information (messages) about the currently selected function. The right side of the status bar provides information on: w w w w w w w Whether or not the benchtop router is homed Whether or not the Caps Lock key is activated Whether or not the Num Lock key is activated The line the cursor is on, and the total lines in the program Whether or not the current NC part program is locked Whether or not the current NC file has been modified The current time according to your computer
When the indicator is dimmed, the function is in the off condition. As you move the mouse around the screen, observe the message area on the left side of the bar. Q Q Which indicators are on and which are off? Does the clock read the correct time?
File modify state Num Lock state Current function Home state
Cap Lock state Current Line: Total Lines File Lock state Current time
3-8
Task 3-9 Position Readout

The Position Readout provides information on the current X, Y and Z coordinates of the tool position. The units of measure in the Position Readout are determined by the Units command under the Setup Menu.
Task 3-10 Machine Info Panel

The Machine Info Panel provides information on the current tool, tool diameter, feed rate, spindle speed, number of passes made, coordinate system in use, as well as the current block and total number of blocks in the program. When a part program is running, the Info Panel also provides display of the elapsed machining time and highlights the block of code that is currently being executed.
Elapsed time indicator
Current, previous and next block
3-9
Task 3-11 Verify Window

The Verify Window allows you to see what the finished workpiece will look like without running the machine. When you select the Verify command from the Program Menu, or when you click the Verify Program button on the Standard Tool Bar, all the tool motions are shown on the screen. After the verify program is run, you can see what your final part will look like. Tool path verification can be performed in centerline view or solid view. Centerline view shows a line drawing of the tool and workpiece, and is based on the centerline of the tool. Solid view is a solid representation of the tool and workpiece. You will learn more about verification in an upcoming activity.

Q Q What are some of the advantages of having a computer control a mill rather than a person? Do you think this is better than having a person do the controlling? More economical?

w w w w w w Return all materials to their proper place at your lab station. Complete the Inventory Checklist for your station. Select Exit from the File menu to exit the control program. Shut off the router and the controller box. Select Shut Down from the Start menu on the computer Shut off the computer.
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Activity 4
Mounting the Stock

OBJECTIVES In this activity you will: w w w w SKILLS In this activity you will develop the following skills: w w w w w w w w MATERIALS For this activity you will need the following materials: w w w w w w This Manual The Benchtop Router The computer and control program Hold down clamps (2) A ruler (metric or standard) A workpiece (Wood) Technology: Systems: Resources: Interpersonal: Information: Basic: Thinking: Personal: Use and Maintain equipment and computer programs Use systems Manage time Participate as a member of a team Acquire / evaluate information Reading and writing Learning Responsibility and self-management Install the clamps on the hold down table Mount a workpiece Learn to select and size the workpiece in Control Program Learn to use and change settings in the Verify window
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OVERVIEW
VISES A mechanical vise is a device designed to use two properties of physics, ramps and levers, to hold an object stationary while some other action is taking place, such as machining. It uses a screw (ramp) and a lever at the end of the screw to clamp around the object of your choice. There are also pneumatic vises, which employ air volume and pressure in a cylinder to secure an object. Hydraulic vises use the same principles as pneumatics, but rather than air, they utilize fluid power. In this situation, we will be clamping a mechanical vise around a 4.5 x 2 x 0.75 wood workpiece to hold it secure while the router operation takes place. But first we have to install the clamps on the hold down table.
PROCEDURES

w w w Check that all materials required for this activity are available at your lab station. Verify that your lab station passes the safety guidelines. Complete the inventory and safety checklists on the worksheet for this activity.
Task 4-2 Mount the Stock and Clamps

The Router should not be powered on yet. If your machine is on, switch it off with the red switch on the controller box. We will be going through the power up sequence later in this activity. 1. 2. 3. Locate the clamps and hardware in your accessories package. Open the enclosure door. There are rows of threaded holes to insert the studs for the clamps. You will be setting the clamps in the second row from the front. Insert the studs in the two middle holes of the second row. You can either start the studs in the holes and then place the clamps down over the studs, or you can thread the nuts on the studs and put them through the clamps into the holes.
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4.
Slide the stock you will be using under the clamps and center it between the clamps. Make sure the clamps are on the edge of the stock. If the clamps are mounted too far in on the stock, the tool will hit the clamps while trying to cut the stock. Use a ruler and measure 4 inches in from the edge of the hold down table to the edge of the stock. Measure in at least 2 places to be sure the stock is square on the table. Tighten the clamps down using the 11/16 wrench.
5.
6.
After you have tightened the clamps, check again that the stock is square on the hold down table.
Task 4-3 Starting the Control Program

From Windows 95: When the Windows desktop appears, select Start from the Task Bar. From the Start menu, select Programs and then the BenchRouter folder. In that folder, select BenchRouter.
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Task 4-4 Setting the Stock Parameters

Now that you have a workpiece mounted, you need to tell the control program what that stock looks like. The control program will update the graphic of the workpiece in the Verify Window. This will be important later when you are verifying an NC program. 1. 2. 3. Select the Program Menu and choose Verify from the pull down menu. The Verify Setup dialog box appears. The View tab should be selected. In the Style box, make sure Solid is selected. This will show the workpiece as a solid block. Centerline will show the workpiece as a line drawing.
4. 5.
Select Isometric to display a three dimensional view of the part. Select the Stock tab.
4-4
6. 7. 8.
Enter the stock dimensions for the workpiece. The stock dimensions are X=4.5, Y=2 and Z=.75. Be sure the Origin is set to zero on all three axes. Select OK to enter your values into the program and to close the dialog box.
Did the graphic in the Verify window change at all?

Q Q Q What are 2 types of vises? What basic principles does a mechanical vise use to hold an object in place? What does a pneumatic vise use to secure an object?
Task 4-6 Inventory Check and Shut Down

w w w w w w Return all materials to their proper place at your lab station. Complete the Inventory Checklist for your station. Select Exit from the File menu to exit the control program. Shut off the router and the controller box. Select Shut Down from the Start menu on the computer. Shut off the computer.
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Activity 5
Tooling
OBJECTIVES In this activity you will: w w w w SKILLS In this activity you will develop the following skills: w w w w w w w w MATERIALS For this activity you will need the following materials: w w w w w w This Guide The Benchtop Router The computer and control program Tool holder Cutting Tool (0.125 inch Router bit) Worksheet for this activity Technology: Systems: Resources: Interpersonal: Information: Basic: Thinking: Personal: Use equipment and computer programs Understand systems - mechanical and computer Manage time Participate as a member of a team Acquire / evaluate information Reading and writing Learning Responsibility and self-management Install the Tool holder onto the Spindle Mount a tool in the spindle Define the tool in the Control Program Select the tool for verification.
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OVERVIEW Using the right tool for the job always makes the job go smoother. The same is true for router operations. There are different types of tools to achieve different results and finishes. Selecting the right tool for the job will increase productivity, give you the correct finish for the part, and help maintain a safe work area. Router bits come in different sizes and shapes, and can be used to create a variety of surface finishes. There are straight bits with single or multiple flutes (cutting edges) for milling grooves and other basic operations; V-shaped bits for lettering on signs; dovetail bits for joinery; beveled and rounded bits for creating a molded edge. There are also bits with guides built onto them, to help keep a hand held router true when following a contour. Those bits are not necessary (and will not work) on the CNC Router, because all motions are programmed into the NC file. Having a guide on the end of the bit also makes it impossible for the Benchtop Router to plunge into the workpiece. To keep things simple, the activities here use straight bits. However, in planning some of your own projects, you may be able to substitute a straight bit for a V-tip or bevelled edge bit. PROCEDURES

Task 5-2 Start the Benchtop Router

Start the Control Program: w w w w w w Power up the computer (always do this first). Switch on the Controller Box. Release the Emergency Stop Button if it is not already pulled out.
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Task 5-3 Installing a Tool

The tool you will be installing is a .125 2 flute router bit. The project you will be cutting on the router in Activity 9 requires this size and type of tool. Cutting tools are extremely sharp. To avoid cutting yourself, it is best to handle them with gloves or using a shop rag. Regardless of which method you use, handle with care. 1. 2. 3. Using the Jog Control Panel, jog the spindle head high enough away from the table to allow you to access the collet. Press the Emergency Stop button, and open the enclosure door. Remove the brush from the spindle head. There is a single thumbscrew on the front of the brush. Loosen this screw and swing the brush down. Pull the brush forward slightly and then down again to remove it. There are 2 large wrenches included in the hardware kit. These are the collet wrenches. After removing the spindle brush, you should be able to see the two nuts on the spindle that hold the tool. If there is no collet installed on the router, locate the collet in the accessories package, and install it on the spindle head. If there is a tool in the spindle, use the wrenches to loosen the collet nut.
4.
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5. 6. 7. 7. 8.
Loosen the collet nut so the tool slides out. You may have to hold the top nut with the wrench to keep the spindle from turning. Install the .125 tool into the collet, and hand tighten the collet nut. Using the wrenches, tighten the collet nut. Do not overtighten! Overtightening the collet nut will cause damage to the nut or to the threads on the spindle. Replace the brush around the spindle head. Close the door and release the Emergency Stop button.
Task 5-4 Define the Tool

The Control Program again needs to know what you changed when you installed the tool in the spindle. So in order for the control program to do the job right, we must give it the correct information. The tool you installed, and will be using in the program you will run in a later activity, was a 0.125 carbide tipped, double flute router bit. This is the tool we will define in the Tool Library, and then select for use in Verification.
Task 5-5 Add the Tool to the Library

1. 2. 3. 4. 5. 6. When the Control Program screen opens, select Setup Library from the Tools Menu. The Setup Tools dialog box appears. In the Tool Library scroll box, select Tool 1. In the Tool Type pull-down list, select End Mill. Enter 0.125 Double Flute in the Description box. Enter 0.125 in the Diameter box. In the Material Type box, select Carbide.
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7. 8.
Click on the Apply button. You have just defined a new tool in the library. Now anytime you need a .125 carbide-tipped, double flute router bit, it will be there. Click on OK to exit the Tool Library.
Task 5-6 Select Tool for Verification

1. 2. 3. From the Tools menu, choose Select Tool. When the dialog box appears click on the tool drop down menu, and choose Tool 1. Click on the Select Tool button at the bottom of the dialog box.
Congratulations, you have successfully installed, defined, and selected the router bit.
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Task 5-7 Questions

Q Q Q What type of tool would you use to cut a contoured shape from a workpiece? It is perfectly safe to handle cutting tools with your bare hands. True or False You should never leave any tools or other hardware in the enclosure. True or False

Q How would it affect the control program if you had not defined the tool, or if you input the wrong information?

w w w w w w w Return all materials to their proper place at your lab station. Return machine to the Home position. Complete the Inventory Checklist for your station. Select Exit from the File menu to exit the control program. Shut off the router and the controller box. Select Shut Down from the Start Menu on the computer. Shut off the computer.
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Activity 6
Home Positions
OBJECTIVES In this activity you will accomplish the following: w w w SKILLS In this activity you will develop the following skills: w w w w w w w w MATERIALS In this activity you will need the following materials: w w w Benchtop Router Computer with the Control Program installed Worksheets for this activity Technology: Systems: Resources: Interpersonal: Information: Basic: Thinking: Personal: Maintain equipment Understand a system Manage time Participate as a member of a team Acquire / evaluate information Reading and writing Learning Responsibility and self-management Set Machine Home Position Learn about Coordinate Systems Set the workpiece origin
6-1
OVERVIEW In order for the router to locate the workpiece on the hold down table, it must have a set of reference points to start from. The first of these reference points is the machine zero, or home position. The home position of the Benchtop Router is preset at the factory, and the machine will automatically move the spindle head there when commanded. You move the machine to the home position either by a command in an NC program, or by opening the Set Position dialog box, and clicking on the Home button. It is good machining practice to home the router every time you turn it on and before you shut it off at the end of the session. Home position on the Benchtop Router is the top (Z axis) front (Y axis) left (X axis) corner of the work envelope. The work envelope is the entire area that the tool may travel while in the spindle. In other words, Home is at the end of each axis of travel. In this situation, it is the negative end of the X and Y axes, and the positive end of travel on the Z axis. The other reference point the machine needs is the workpiece origin. In order to cut a part, the control program must be able to locate the workpiece on the hold down table. You must teach the program where the start point of your NC program is. Workpiece origin is usually the top, front, left corner of the workpiece. PROCEDURES


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Task 6-3 Home the Machine

When the Control Program is up and running, select Set/Check Home from the Setup Menu. 1. 2. 3. The Machine Home Reference Point dialog box appears. Click on the Home button. The machine moves the spindle to the top front left corner of the work envelope.
Q Q
What is Machine Home? Where is Machine Home?
Task 6-4 Set Workpiece Origin

To be able to actually see when the router bit is at the top front left corner of the workpiece, you must have two things: The tool mounted in the spindle; and the brush removed from the spindle head. The tool should be mounted in the spindle from the last activity. If it is not, follow the steps outlined in Activity 5 to remove the brush and mount the tool in the spindle. 1. 2. Select Jog Control from the View Menu (or the Standard Toolbar). The Jog Keypad appears. Use the Jog Keypad to jog the tool to the top of the front left corner of the workpiece.
+Z
Tool
+Y
(0,0,0)
Point of Origin
+X
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3. 4.
Select Set Position from the Setup Menu. The Set Position dialog box appears. Enter zero in the X, Y and Z boxes.
5. 6. 7.
Click on OK. The values in the Position Readout all change to zero. From the Setup Menu, select Set/Check Home. When the dialog box appears, click on the Move Home button. This will move the spindle to the machine home position. Any time you run the machine you should return the spindle to the home position before you shut down. Do you think you could set the workpiece origin somewhere other than the front left corner of the workpiece?
ACADEMICS
UNDERSTANDING COORDINATE SYSTEMS By setting the machine home and the workpiece origin, you have given the router a set of coordinates from which to work. Since all NC programs consist of moving the cutting tool from coordinate to coordinate, this is very important. Activity 11 explains in more detail coordinate systems and how they are used in NC programming. This is a brief overview. For a beginning user, understanding coordinate systems can be difficult. The first thing to remember is before performing any machining operations, you are required to set the machine to home position. This returns the machine to the machine zero point, and acts as a reference point for all operations. It is a good idea to home the machine at power on.
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Machine Coordinates
Machine Zero positions the router head at the extreme negative end of travel on the X and Y axis, and the extreme positive end of travel on the Z axis. This is a fixed point on the machine, and cannot be changed. The machine uses this as a reference point for all operations. If the machine is not homed (set to the machine zero) it can not accurately locate the workpiece on the hold down table. The machine is homed by selecting Set/ Check Home under the Setup menu, and choosing the Home button; or by using a G28 code in the NC program.
Work Coordinates
Once home is set, you load an NC program into the computer. Your program will need a point of origin to start from. Setting a point of origin will establish the work coordinates. Work coordinates relate to the workpiece, and are usually set from the top of the front left corner of the workpiece mounted on the table. Once the stock is mounted on the table, jog the spindle to the top, front, left corner of the workpiece. From the Setup Menu, select Set Position. The tool coordinates appear in the dialog box. Enter 0,0,0 and click on OK to set the current tool position as the point of origin on the workpiece.
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Q Q Q
What is a Coordinate System? What NC code can be used to Home the system? What is another name for Work Coordinates?

Q What do you think would happen if you set the workpiece origin first, and then homed the machine, to the wrong position?

w w w w w w w w Return all materials to their proper place at your lab station. Return the machine to the Home position Complete the Inventory Checklist for your station. Return the machine to the Home position, if you have not done so already. Select Exit from the File menu to exit the control program. Shut off the router and the controller box. Select Shut Down from the Start menu on the computer. Shut off the computer.
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Activity 7
Selecting an NC Program
OBJECTIVES In this activity you will accomplish the following: w w w SKILLS In this activity you will develop the following skills: w w w w w w w w MATERIALS In this activity you will need the following materials: w w w Benchtop Router Computer with the BenchRouter Control Program installed Worksheets for this activity Technology: Systems: Resources: Interpersonal: Information: Basic: Thinking: Personal: Work with computer file systems Work with computer file systems Manage time Participate as a member of a team Acquire / evaluate information Reading and writing Learning Responsibility and self-management Power on and off the benchtop router system Load an NC file into the control program Adjust verification settings
7-1
OVER VIEW In order to cut a part from a piece of stock, the router must have a set of instructions to tell it what to do. These instructions are what we call the NC program. Using information such as the workpiece origin, coordinates on the X, Y, and Z axes, and a set of special NC codes, the program tells the router where to move, how fast to move (feed rate), and how fast to turn the spindle (spindle speed). For this activity you will be using the program called Domino.NC. You will need to find the program on the computer file system and load it into the control program in order to run it. Once it has been brought into the control program, you will be setting various operating parameters before you verify and run the program. PROCEDURES


Task 7-3 Selecting an NC Program

First, you must locate the Domino program on your computer's hard drive, and open it in the control program.
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1. 2.
Select the Open command from the File menu, or click on the Open button on the Standard toolbar. The Open dialog box appears. The dialog box will display the BenchRouter folder, which contains a number of sample programs. Double click on the filename Domino.NC, or click on the filename and then click on the Open button. The Edit window will appear with the Domino.NC program displayed. Take a moment to look at the file.
3.
What is an NC program?
When you first open an NC program in the Edit window, it is locked. There are two ways you can tell that it is locked; it has a gray background, and LOCK will be in black on the Status bar at the bottom of the screen. Unlocking a file in the edit window allows you to make changes to the code. This is important if you have problems running the program. You can immediately stop the program, and if you are sure of the codes that must be changed, you can edit it right there without having to consult the programmer. Unlock the NC program by selecting Unlock from the Edit menu. Q What happens to the file in the edit window? The Status Bar?
Select Lock from the Edit menu and lock the file again. Before you run the program, you must verify and dry run it.
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Task 7-4 Adjust the Verify Settings

To adjust the settings you first need to open the Verify Setup dialog box. Do any one of the following: w w w w Double click on the Verify window; Select the Program Menu and choose Verify from the pull down menu, or; Select Verify from the Standard Toolbar and choose Verify Settings. The Verify Setup dialog box appears.
Task 7-5 Adjust the View

1. 2. 3. Q Select the View tab. Select either Solid or Centerline (for a solid representation or a centerline representation of the tool and workpiece). Select Isometric for a three dimensional view of the part. Why would you want a different view of the part in the verify program?
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Task 7-6 Adjust the Stock

1. 2. Select the Stock tab. Enter the stock dimensions for the Domino.NC program. The stock dimensions are X=4.5, Y=2, Z=.75.
3. 4. 5. Q
Set the Initial Tool Position to X=0, Y=0 and Z=0.5 Set the point of origin to zero on all three axes. Select OK. The dialog box will close, and you should notice a change in the shape of the workpiece in the Verify Window. What might happen if you put the wrong sizes in the stock window?
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Task 7-7 Select the Tool for Verification

The tool required for Domino is specified in line N3 of the NC program. It calls for a 0.125 double flute router bit. You will need to select this tool in the control program as well. If you recall, you added a 0.125 double flute router bit to the tool library in Activity 4. 1. 2. 3. Select Tool from the Tools Menu. The Select Tool for Use dialog box appears. Select Tool 1 from the pull-down list. Click on the Select Tool button.
4.
Select Save from the File menu to save all your settings.
Task 7-8 Team Discussion and Review

Q Q How does the computer file system make it easier to operate the computer? What are some of the things the NC program controls?

w w w w w w w Return all materials to their proper place at your lab station. Return the router to the Home position. Complete the Inventory Checklist for your station. Select Exit from the File menu to exit the control program. Shut off the router and the controller box. Select Shut Down from the Start Menu on the computer. Shut off the computer.
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Activity 8
Verify and Dry Run the Program

OBJECTIVES In this activity you will accomplish the following: w w w SKILLS In this activity you will develop the following skills: w w w w w w w w MATERIALS In this activity you will need the following materials: w w w w w Benchtop Router Computer with the BenchRouter Control Program installed Worksheets for this activity Workpiece, mounted on the hold down table Tool, mounted in the spindle Technology: Systems: Resources: Interpersonal: Information: Basic: Thinking: Personal: Maintain equipment Understand a system Manage time Participate as a member of a team Acquire / evaluate information Reading and writing Learning Responsibility and self-management Learn how to verify an NC program Estimate the time to run a program and the distance the spindle will travel Dry run the Domino.NC program.
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OVERVIEW At this point you are probably wondering when you're actually going to see this machine cut some parts. Well, before we get to that, there are a few more things we need to do. First we will estimate the run time of the program, and find out why this is helpful to know. Then we will do a graphic verification of the nc program. This is very important, because it allows us to see what the finished part will look like without actually cutting the part. And the final step before cutting any part is a dry run, which means running the router through all the motions with no stock mounted. PROCEDURES


8-2

Before you perform any operation with the Benchtop Router it is important that you home the machine. It is good practice to home the machine at start up. 1. 2. 3. From the Setup Menu, select Set/Check Home. In the dialog box that appears, click on Home to home the router. The router moves to the home position.
Task 8-4 Estimate Run Time

The Estimate Run Time function allows an operator to estimate how long a program will take to run, and the approximate distance the machine travels while machining the part. This is good to know if you are working on a tight schedule, or if you need to schedule a certain number of jobs in a short time. Estimate Run Time also verifies the way your NC programs are written. If it finds an error in the coding, the program will alert you, and place the cursor near the error. 1. 2. Q Q Q Q Q Open the Domino.NC file. From the program menu, select Estimate Run Time. What happens? What information does the dialog box give you? How long will the Domino program run? How far will the spindle travel? Why would you want to know how long a program will run? What other reasons are there for knowing the runtime?
8-3
Task 8-5 Verify Domino.NC

You set the graphic verification parameters in the last activity, and saved them before exiting the program. If you did not, or can't remember, select the Verify Settings dialog box and check. When you are satisfied that the settings are correct, continue here. Tool path verification allows you to check for programming errors before actually running the part program on the Benchtop Router. It gives also gives you a chance to see a picture of the part being machined, without running the router. 1. Select Verify from the Program Menu or from the Standard Tool Bar. The Verify Program dialog box appears. The default starting line for the program is Line 1. When verifying a program, you should always begin on Line 1. Click on the Verify Program button, then watch the Verify Window. You will see theDomino.NC program executed on the graphic workpiece.
2.
If there are any problems, the message bar at the top of the screen will turn red, and a message will appear in the middle of the screen. Q Q Q How does tool path verification check the program for errors? Did your program run through verification without any problems? If not, what were the problems? How did you fix them?
8-4
Task 8-6 Dry Run the NC Program

A dry run is when you run the program with no stock mounted. This is important because it give you the chance to see if all the movements of the router make sense, and that the tool is in no danger of striking any fixtures or crashing into the workpiece. Although the dry run is performed with no stock mounted, you still need to set the workpiece origin. After you have done that, you will remove the workpiece. Begin with the Emergency Stop button pressed in, and the spindle speed turned all the way down. The clamps or other work holding device should be mounted to the hold down table. 1. 2. 3. Mount the workpiece on the table. Mount the tool in the spindle, and leave the brush off to set origin. Close the Safety Shield and pull out the Emergency Stop button.
4. 5. 6.
Select Jog Control from the View Menu (or the Standard Toolbar). The Jog Keypad appears. Use the Jog Keypad to jog the tool to the top of the front left corner of the workpiece. Select Set Position from the Setup Menu. The Set Position dialog box appears.
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7. 8. 9.
Enter zero in the X, Y, and Z boxes. Click on OK. The values in the Position Readout all change to zero. Jog the tool up and away from the workpiece. Press the Emergency Stop button, open the Safety Shield and remove the workpiece. For the dry run, leave the brush off the spindle head.
10. Return the Safety Shield to the closed position and pull out the Emergency Stop button. 11. Put on a pair of safety glasses and complete the Safety Checklist. 12. Select Run/Continue from the Programs Menu. The Run Program dialog box appears. 13. Click on the Run Program button. As the part program runs, watch the tool motion in relation to the clamps (and eventually the workpiece). Look for signs of a possible tool crash and be prepared to press the Emergency Stop button on the router. Q Q Q What is a Dry Run? What are the things to look for during a dry run? Did you get any error messages while the program was running? How would you correct them if you did? If you had to edit the program at all, be sure to save your changes before you exit the program.

Q Why do you think it is so important to verify the NC program in different ways before actually cutting the part? What are some of the dangers of just running the program?

w w w w w w w Return all materials to their proper place at your lab station. Return the machine to the home position. Complete the Inventory Checklist for your station. Select Exit from the File menu to exit the control program. Shut off the router and the controller box. Select shut down from the start Menu on the computer. Shut off the computer.
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Activity 9
Run the NC Program

OBJECTIVES In this activity you will accomplish the following: w w w SKILLS In this activity you will develop the following skills: w w w w w w w w MATERIALS In this activity you will need the following materials: w w w w Benchtop Router Computer with the BenchRouter Control Program installed Worksheets for this activity Wood Stock Technology: Systems: Resources: Interpersonal: Information: Basic: Thinking: Personal: Use CNC equipment safely Use the computer system Manage time Participate as a member of a team Aquire / evaluate information Reading and writing Learning Responsibility and self-management Mount the Stock Set Machine Home and Workpiece Origin Safely run the NC program, and successfully cut a part
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OVERVIEW This is the activity where you will finally get to see the Benchtop Router in action. We will be cutting the part. Remember that safety is of the highest importance when operating any machine, and this is no exception. You are expected to complete all the safety checks, abide by the operation guidelines, and be ready to halt machine operation instantly should any problem arise. Above all, pay attention to what the router is doing. Good Luck! PROCEDURES

Task 9-2 Power up the Benchtop Router

From Windows 95: When the Windows desktop appears, select Start from the Task Bar. From the Start menu, select Programs and then BenchRouter folder. In that folder, select BenchRouter .

w w When the Control Program is up and running, select Set/Check Home from the Setup Menu. Click on the Home button to home the machine.
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Task 9-4 Mount the Workpiece

1. 2. 3. 4. Using the Jog Keypad, jog the spindle up and out of the way. Push the Emergency Stop button in, and open the Safety Shield. Mount the stock on the hold down table. Pull the Emergency Stop button out.
Task 9-5 Install the Tool

w w Install the 0.125 router bit in the spindle as instructed in Activity 4. Close the Safety Shield, and pull the Emergency Stop button out.
9-3

1. Jog the tool to position the center of the tool tip at the top of the front, left corner of the workpiece. Jog until the tip of the bit touches the surface of the workpiece. Select the Set Position command from the Setup Menu and enter zero for all three axes.
+Z
2.
Tool
+Y
(0,0,0)
Point of Origin
+X
Task 9-7 Verify all Settings

1. From the tools menu, choose Select Tool and verify that tool 1 is selected.
2.
From the Setup menu, select Verify Settings and check you have the correct values in the boxes.
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3.
Select the Operator Panel and check that the spindle speed is set to 100%.
Task 9-8 Run the Program

Before executing the Domino.NC program, check that all safety precautions have been taken. The router safety shield should be closed, the brush should be installed on the spindle head, and you should be wearing safety glasses. If anything goes wrong, immediately press the Emergency Stop button on the Benchtop Router to stop the operation. To run the program: 1. After reviewing the Safety Checklist, select the Run/Continue command from the Program Menu. The Run Program dialog box appears.
2. 3. 4.
Make sure that the Start Line box is set to line 1 of the program. Click on the Run Settings button. The Run Settings dialog box appears. The Run Settings dialog box should look like the one pictured here. The only box that should be checked is the Verify While Running box.
9-5
5. 6. Q Q Q
Click on the Run Program button to begin running your program. After the part is cut, press the Emergency Stop button before opening the safety shield and removing the finished part. Where on the control program screen does it tell you the run time of the program? Check your worksheet from Activity 8. How long did it actually take to run the program? Was the Estimate Run Time function correct?
Task 9-9 Discussion and Reveiw

Q Q Did you encounter any problems while running the Domino program? Would you like to learn more about NC programming, so that you could design your own projects? What kind of things would you like to cut on the router?

w w w w w w Return all materials to their proper place at your lab station. Return the machine to the home position. Complete the Inventory Checklist for your station. Select Exit from the File menu to exit the control program. Shut off the Benchtop Router and the controller box. Select Shut Down from the Start Menu.
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Activity 10
NC Programming
OBJECTIVES In this activity you will accomplish the following: w w w SKILLS In this activity you will develop the following skills: w w w w w w w w MATERIALS In this activity you will need the following materials: w w w Benchtop Router Computer with the BenchRouter Control Program installed Worksheets for this activity Technology: Systems: Resources: Interpersonal: Information: Basic: Thinking: Personal: NC programming Learning how an NC program works Manage time Participate as a member of a team Acquire / evaluate information Reading and writing Learning Responsibility and self-management An understanding of numerical control programming. Recognize NC words and their component address codes and parameters Detect errors in NC code blocks
10-1
OVERVIEW
WHAT IS NC PROGRAMMING? Before a part is machined, every step in the machining process must be described in a part program. The program, or list of instructions, is written in a language that can be understood by many CNC machine tools. The language is called the EIA RS-274D standard format, or G&M code programming. In this module, you will learn how to write NC words using EIA RS-274D codes, and how to combine the codes to form an NC part program. This is a typical block of NC code. N5G90G01X2Y3Z2 These are the individual NC words that make up the block. N5 G90 G01 X2 Y3 Z2
ELEMENTS OF A PART PROGRAM Part programs use two types of instructions: those that define the tool path (such as X and Y axis coordinates), and those that specify machine operations (such as turning the spindle on or off). An NC part program is made up of blocks (lines) of code. Each code block contains a string of words. An NC word is made up of an alphabetic character (the address character) and a number (the parameter). For example, the coordinate X2 has the address character X and the parameter 2. The address characters you will use for your NC part programs are N, G, X, Y, Z, I, J, K, F, S, T, M, and the semicolon (;). The character N is used in words that number the blocks of code in a program. For instance, the first block in a program begins with the word N0. The next block begins with N1. The next blocks are N2, N3, N4 and so on. The N word is always the first word in each block. The character G is used to create preparatory codes. Preparatory codes tell the Benchtop Router what kind of cut to make and which programming mode to use. G words are always written before any instructions that tell the Benchtop Router to move the tool. The character X is used to tell the tool where to move to (absolute) or how far to move (incremental) on the X axis. If you are working in absolute programming mode, the word X2 tells the Benchtop Router to move the tool to the coordinate X2. In incremental programming mode, the tool would move 2 units from its current position. The character Y is used to tell the tool where to move to (absolute) or how far to move (incremental) on the Y axis. The character Z is used to tell the tool where to move to (absolute) or how far to move (incremental) on the Z axis.
10-2
I, J and K words tell the tool the X, Y and Z coordinates of the center point of an arc (for circular interpolation). In absolute programming, I words represent the X coordinate, J words represent the Y coordinate and the K words represent the Z coordinate. In incremental programming, the I, J and K words specify the distance from the start point to the center point of the arc. The character F is used in words that tell the tool what feed rate to use to move the tool into the workpiece. The parameter represents the rate of speed in either inches or millimeters per minute (the units are set by the programmer). For instance, the word F2 means to move the tool into the workpiece at a rate of two inches per minute. The character S is used in words to specify spindle rotation speed. The parameter defines the speed at which the spindle rotates in revolutions per minute (RPM). The character T is used in words that define the tool, if more than one tool is used. The parameter in the T word is the number assigned to the tool. For instance, tool #1 (T1) can be an 1/8" end mill, while tool #2 (T2) is a 1/4" end mill. The character S is used in words to represent miscellaneous machine operations. These operations vary from turning the spindle on and off (M03 and M05), to repeating the NC program (M47). A semicolon ( ; ), or comment code, allows you to attach comments, or reminders, to each block of code. These reminders usually contain information about the words in the block. For instance, the comment in this block N2M03;TURN SPINDLE ON tells you exactly what the function of the block is. Any characters that appear after a comment code are not acted upon by the Benchtop Router. Here is another example:
N5G90G01X2Y3F2; GO TO START POINT AT 2 IPM
Any text following the semicolon is a comment, and has to be on the same line as the semicolon.
10-3
Some NC words are used more often in part programs than others. Here are some of the more common NC words. The G codes are broken into several groups.
G CODES
G00 G01 G02 G03 G04 G05 G90 G91 Rapid Traverse: Move rapidly to the indicated position. Rapid traverse motion does not necessarily mean the tool moves in a straight line. Linear Interpolation: Move in straight lines. Circular Interpolation, Clockwise: Move the tool in an arc in a clockwise direction. Circular Interpolation, Counterclockwise: Move the tool in an arc in a counterclockwise direction. Dwell (wait): A timed pause equalling the F-code value in seconds. Pause: Pause until the Return key is pressed. You can also use M00. Absolute Coordinates: Move the tool to the place in the program defined by X, Y, or Z. Incremental Coordinates: Move the tool the distance defined by X, Y, and Z in the program.
M CODES
M00 M02 M03 M05 M06 M47 Pause: Pause until the Return key is pressed. You can also use G05. End of Program: This is the last instruction in the program. Spindle On: Turns on spindle motor. Spindle Off: Turns off spindle motor. Tool Change: Pauses all operations, turns off spindle, retracts spindle for tool change. Rewind: Repeats the program. If rewind is used, you must place a G05 or M00 pause at the beginning of the program.
10-4
New Terms
Address Character - An alphabetic character representing a command in an NC word. EIA RS-274D Standard Format - Standard for NC programming established in 1979 by the Electronics Industries Association, also called G&M code programming. Block - A word or group of words making up one line of an NC program. Code - In NC programming, the same as a word, typically used for G and M words, also a general term for a set of programming instructions. Parameter - Numbers that describe movement or distance, and are used with an address character command in an NC word. Part Program - A list of numerically coded instructions. Preparatory Code - NC words (G address character plus a parameter) that tell the machine tool what type of interpolation and programming mode to use. Word - The combination of an address character (the command) and a parameter (the distance or movement).
Programming Suggestions
There are nine basic guidelines to follow when writing NC programs. 1. The sequence of words (address characters plus parameters) in an NC block must appear in the following order when more than one address character is used per block: N, G, X, Y, Z, I, J, K, F, S, T, M, ; Only one of each address character can be used per block, except some G codes. For instance, you can place one G code from the Interpolation Group and one G code from the Programming Mode Group in the same block. However, you can not place two codes from one group in the same block. Example: The block, N1G01G90X2X2, is incorrect because is has two X codes. The use of the G codes, however, is correct because one G code is from the Interpolation Group and the other is from the Programming Mode Group. The block, N1G00G01X2Y2, is incorrect because it uses two G codes from the same group. 3. Some codes dont have to be repeated in every block. The router will use the same value until you change it. Example: N3G01X.5Y2F1 N4Y3.5
2.
10-5
In block N3 the tool is instructed to move in a straight line (G01) to X.5,Y2 at a feed rate of 1 inch per minute. In block N4 the tool is instructed to move to 3.5 on the Y axis, but the feed rate, linear interpolation (G01), and X value remain the same as in block N3. Its not necessary to repeat that information. 4. The first block in a program should move the tool away from the workpiece to a safe point (where the tool is not touching the workpiece) to turn on the spindle. Example: N0G00G90Z.1 N1M3 5. Don't forget; the second block in a program should turn on the spindle. Example: N1M3 6. The third instruction in a program, after the spindle is turned on, should move the tool to the start point, the point where machining begins. Example: N2G00G90X.5Y.5 Block N2 tells the tool to move in rapid traverse to absolute coordinates X.5 and Y.5. 7. The end of a part program should move the tool back to the start point so the tool will be ready to cut the next part. Example: N5G0Z.1 N6X.5Y.5M5 N7M2 If these were the last three blocks in the program, the tool would move back to the start point X.5,Y.5,Z.1, the spindle would be turned off, and the program would end. 8. The maximum number of characters allowed in one block is 66. In order to save space, you can leave out extra zeros as long as they have no affect on the value. For instance, you can write N6G00X0.500Y1.500 as N6G0X.5Y1.5 saving six characters. But, you can not write N2G90Z0.05M00 as N2G9Z.5M because theres no such thing as a G9, the Z value has changed from .05 to .5, and the M address character has been left without a parameter.
10-6
9.
If you are just learning to program, and youre not sure about how to combine codes in a block so the correct action is performed first, put each G and M code in a separate block. Example: N7G0X.5Y2M5 can be written as N7G0X.5Y2 N8M5 If you want to make sure the spindle will turn off after you move to the X and Y positions in this block, you should put the M5 in the next block.
PROCEDURES
Task 10-1 Questions

Briefly answer the following questions. 1. 2. 3. What is a part program? What are the two parts of an NC word? Here are some new terms you learned in this module. Write a brief definition of each term. CodeAddress CharacterWordEIA RS-274D Standard FormatParameterBlockPreparatory Code4. Match the NC words in the first column to their correct meaning in the second column. _____M02 _____G90 _____T1 _____J.5 _____G00 _____X2.5 _____N12
a. Move the tool to 2.5 on the X axis (absolute) b. Move the tool to .25 on the Z axis (absolute) c. Move the tool rapidly to the indicated position d. Make the center point of the arc .15 on the X axis e. Use clockwise circular interpolation f. End of program g. Turn off the spindle motor
____G02 _____F1 _____Z.25 _____I.15 _____M05 _____G91 5.
h. Make the center point of the arc .5 on the Y axis i. Use incremental coordinates j. Use absolute coordinates k. Move the tool at a feed rate of one inch per minute l. This is the block marked number twelve m. Use tool #1
Some blocks from an NC program are listed below. Each block contains several words. Write an explanation of each word in the space provided. Explanation N0 G0 _________________________ _________________________
Block N0G0G90Z.1
G90 - _________________________ Z.1 N1M3 N1 M3 N2G1X2.5Y3F2 N2 G1 _________________________ _________________________ _________________________ _________________________ _________________________
X2.5 - _________________________ Y3 F2 N43G0Z.1 _________________________ _________________________
N43 - _________________________ G0 Z.1 _________________________ _________________________
N44M2
N44 - _________________________ M2 _________________________
10-8
6.
What is wrong with the following NC blocks? Some of these blocks will actually work, but are not written in the best way according to the programming rules. N1X.5Y.5G90 N29G0X.5Y.5M2M47
N3X.5Y.5F2 N4X.5Y1.5F2 N04X0.50Y0.7500F2.00 N5G0X.25X.5Y1 N6G91X2Y3; MOVE TO ABSOLUTE POSITION X=2 Y=3 N12G1X2Y3,RAPID TRAVERSE TO X2,Y3 N2G9OX2Y3;F1
10-9

If you do not have the control program running on your computer, start it now. Locate and open the Domino program. Q Q Q Does the code in the program make more sense to you than it did before? Can you pick out specific blocks of instruction, such as starting and stopping the spindle? Can you tell what the programmed feed rate was? What else can you see?

w w w w w w w Return all materials to their proper place at your lab station. Return the machine to the home position. Complete the Inventory Checklist for your station. Select Exit from the File menu to exit the control program. Shut off the Benchtop Router and the controller box. Select Shut Down from the Start menu on the computer. Shut off the computer.
10-10
Activity 11
Coordinate Systems
OBJECTIVES In this activity you will accomplish the following: w w w w w w w SKILLS In this activity you will develop the following skills: w w w w w w w w MATERIALS In this activity you will need the following materials: w w w Benchtop Router Computer with the BenchRouter Control Program installed Worksheets for this activity Technology: Systems: Resources: Interpersonal: Information: Basic: Thinking: Personal: Learn detailed information about programming NC code. Use the various systems involved in NC programming. Manage time Participate as a member of a team Aquire / evaluate information Reading and writing Learning Responsibility and self-management Understand coordinate geometry, as well as two- and three-dimensional systems. Understand absolute and incremental programming,. Understand linear and circular interpolation. Plot both positive and negative coordinates in their correct quadrants. Plot coordinates in absolute and incremental programming modes using both linear and circular interpolation. Demonstrate a basic knowledge of how coordinate systems are applied to machining tasks. Demonstrate how coordinate systems relate to the Benchtop Router.
11-1
The first part of this activity introduces two-dimensional and three-dimensional coordinate systems, and coordinate measurement.The second part of this activity introduces absolute and incremental programming, as well as linear and circular interpolation as they relate to the Benchtop Router. It also explains how coordinate systems can be applied to the Benchtop Router. OVERVIEW Part 1 Coordinate Measurement
To make a part on a CNC machine, we must tell the machine exactly where to cut the workpiece. But, how do we know where the machine should cut the workpiece? First, we read the part drawing. The part drawing shows all the dimensions of the part. Using the drawing, we can measure the distance the tool must travel to make cuts. We can also determine the direction in which the tool must move to cut the part. Once we measure the distance and direction of each cut, we can put that information into an NC program. When we enter the NC program into the computer and run it, the Benchtop Router will cut along the path defined by our measurements.
2.000 1.300 1.000 .700
3.000
2.500 1.600 1.000 .700
.500 .500 1.500
NC tool motions are based on coordinate measurement. A coordinate is one of a set of numbers that describe a point on a plane (a flat surface). In numerical control, the tool moves from one coordinate point to another coordinate point. The coordinate system used for NC measurement is called the Cartesian coordinate system. It is named after the man who devised it, 17th century French mathematician Ren Descartes. The theory of his system is that any point can be specified by its distance from another known point.
Student Activities Book 9712 11-2 CNC Technology: Benchtop CNC Router
Two-Dimensional Measurement A Cartesian coordinate system begins with two perpendicular lines. These lines are called the coordinate axes. The two axes are named X and Y. This is a two-dimensional system.
Y AXIS
X AXIS
The two axes are divided into units, forming a grid. The units can be measured in a variety of ways. Units can be measured in whole or fractions of inches; they can represent 0.5 an inch, 1 inch, 5 inches, 10 inches, or whatever value you choose. Units can also be measured in metric values.
Y
5 4 3 2 1 0,0
Point of Origin
X
1 2 3 4 5
The point where the axes meet is called the point of origin. The point of origin is located where the measurement on each axis equals zero. So, the point of origin is given the coordinate of X0,Y0 (or 0,0). If we know the point of origin, we can find any other point on the grid.
11-3
The X and Y axes divide the X and Y plane into four sections, or quadrants.
+Y
Quadrant II (-x,+y)
4 3 2 1
Quadrant I (+x,+y)
-X
-5 -4 -3 -2 -1 -1 -2
0,0 1 2 3 4 5
+X
Quadrant III (-x,-y)
-3 -4 -5
Quadrant IV (+x,-y)
-Y
The X axis coordinates to the right of the point of origin (0,0) have positive (+) values. The X axis coordinates to the left of 0,0 have negative (-) values. The Y axis coordinates above 0,0 have positive values. The Y axis coordinates below 0,0 have negative values. PROCEDURES
Task 11-1 Locating Points

w w The coordinate X2,Y3 is located in Quadrant I. In which quadrant will we find X-2,Y-3? How about X2,Y-3? Using inches as the units, measure 2 inches along the X axis from the point of origin. Next, measure 3 inches along the Y axis from the point of origin. We come to an intersection, where X=2 and Y=3. This point can be given the coordinate X2,Y3 (or 2,3). Note: Always give the X value first. Units can also represent fractions of an inch. Measure 3.5 inches along the X axis and 2.5 inches along the Y axis; the coordinate point is X3.5,Y2.5. Any fraction can be used: .75, .625, .125. (In NC programming, fractions are written in decimal form.)
Task 11-2 Questions

Q Q Q What is a coordinate? What is the theory of Ren Descartes coordinate system? What is the point where the axes meet called, and what is the value on each axis at this point?
11-4
Three-Dimensional Measurement So far we have discussed coordinates based on two axes (X and Y), but many parts made on machine tools are three-dimensional. To design a three dimesional part, we need a three-dimensional coordinate system. The three axes in a three-dimensional system are the X, Y, and Z axes. In three-dimensional measurement, the X and Y axes fall on the same plane. The Z axis is perpendicular to that plane. The point of origin for this system is X=0, Y=0, Z=0.
The Z axis is perpendicular to the X,Y plane.
X,Z plane
Y,Z e plan
TOOL
X,Y plane
X X
Point of Origin (0,0,0)
X,Y plane
Y,Z
Y
plan
X,Z plane
Z
The Right-Hand Rule The Right-Hand Rule is an easy method of remembering three-dimensional coordinates and the direction of motion in relation to coordinates.
+Z +Z +Y +Y
0,0,0
90
+X
90 o
+X
11-5
90 o
Task 11-3 Questions

Q Q How is a three-dimensional coordinate system different from a two-dimensional coordinate system? Draw a two-dimensional coordinate system with X and Y axes. a) Show these four points: X-2,Y3; X4,Y5; X5,Y-1; X-1,Y-1 b) In which quadrant is each of these coordinates located?
Part 2
How Coordinates Relate to the Benchtop Router The Z axis is always the spindle axis. The Z axis on a machine tool can be horizontal (as on a lathe) or vertical (as on a vertical mill). On a vertical mill, or Benchtop Router, the Z axis is vertical (parallel to the spindle). The X and Y axes are horizontal. The X axis is parallel to the machine bed (hold down table), and the Y axis is perpendicular to the X axis. In vertical milling, the point of origin can be located anywhere on the workpiece, but is usually placed on top of the front, left corner of the workpiece. This way, all the work is done in Quadrant I, with positive values for X and Y. When the tool moves into the workpiece, it travels downward in the negative Z direction.
11-6
X and Y motions are always thought of in terms of the tool moving over the workpiece. This is the case with the router, however, on some other mills, the workpiece actually moves beneath the tool.
+Z
Tool
+Y
(0,0,0)
Point of Origin
+X
Absolute and Incremental Programming There are two different programming modes used to instruct the Benchtop Router on how to position the tool, absolute and incremental. When using the absolute programming mode, the position of the tool is always measured from the point of origin (0,0). When using the incremental programming mode, the position of the tool is measured from the last position of the tool. Each time the tool moves, the start point of the new motion is treated as the origin (0,0). Do you see how these two methods differ? Unless otherwise instructed, you should use absolute programming for all your NC programs. It is easier to keep track of the placement of the tool and correct programming errors when using absolute programming. Example: The tool is located at X1,Y1. We want the tool to move to the coordinates X2,Y3. In absolute programming, we instruct the tool to move to 2 on the X axis and 3 on the Y axis (or X2,Y3). In incremental programming, we instruct the tool to move away from its present position. The tool must move 1 inch on the X axis, and 2 inches on the Y axis (or X1,Y2).
11-7
Task 11-4 Absolute and Incremental Questions

Q Using absolute programming mode, give the X and Y coordinates (in order from Start Point to End Point) for each point shown in the illustration below. Start Point: Point A: Point B: End Point: Q Using incremental programming mode, give the X and Y coordinates (in order from Point A to End Point) for each point shown in the illustration below. Point A: Point B: End Point:
Y
5 End Point 4 Point B 3 2 1 Start Point 0,0 Point A
X
1 2 3 4 5
11-8
Interpolation Interpolation means moving from one coordinate point to another along a defined tool path at a programmed rate of speed. Both linear and circular interpolation can be used on the Benchtop Router. Linear interpolation makes straight-line motions between coordinate points. You must specify the beginning and ending points for each line segment. The end point of one line segment is the beginning point of the next line segment. Heres a typical block of NC code using linear interpolation:
N5G90G01X.7Y1.2F2
Broken down into individual words: N5 G90 G01 X.7 Y1.2 F2 The block sequence number is 5 Coordinates are given using absolute dimensioning Linear interpolation is specified X axis coordinate of end point = .7 Y axis coordinate of end point = 1.2 Feed rate is 2 inches per minute
The G01 code is required when switching from circular interpolation or rapid traverse positioning back to linear interpolation. If we assume the current position of the tool is X.5, Y.5, the tool movement generated by the above block is something like this:
11-9
You can use linear interpolation to create arcs, but you would have to program many short, straight-line segments. So, to create arcs you should use circular interpolation. Circular interpolation is both easier and faster for cutting circles or arcs (portions of circles). You must specify the beginning and ending points of the arc, the center of the circle and the direction of the cut. Circular interpolation moves the cutting tool along an arc from the starting point specified in one block, to an end point specified in the next block. The curvature of motion is determined by the location of the center point (I, J, or K), which must also be specified in the second NC block. The direction of rotation from the starting point determines the actual shape of the arc relative to the spindle axis. A G02 code moves the tool in a clockwise (CW) motion from the starting point. A G03 code moves the tool in a counterclockwise (CCW) motion from the starting point.
Here are two typical blocks of NC code using circular interpolation:

N9G90X1Y0;SET START POINT N10G03X0Y1I-1J0F2;COUNTERCLOCKWISE TO X0,Y1
The first block defines the starting point. The second block defines the end point and the center of the arc. Broken down into individual words, the second block reads (Note: this block is written for incremental arc center mode): N10 The block sequence number is 10 G03 The tool will proceed in a counterclockwise direction from the starting point to specified (X, Y) coordinates; center point of arc is specified by (I, J) coordinates X1 X axis coordinate of end point = 0 Y0 Y axis coordinate of end point = 1 I-1 I coordinate of center point of arc = -1 (relative to start point) J0 J coordinate of center point of arc = 0 (relative to start point)
F2 Feed rate is 2 inches per minute
11-10
The tool path generated by the preceding block is something like this:
Y
End Point (X0,Y1)
1
Tool Motion
.5
Start Point (X1,Y0) Center Point
X
.5 1
Task 11-5 Questions

Q Q Q What is interpolation? What kind of motion does linear interpolation use? What two points must be specified for linear motion? What kind of motion does circular interpolation use? What three points must be specified for circular motion?

Briefly answer the following questions. 1. Using linear interpolation and absolute programming, draw an X,Y coordinate system with a tool path for these coordinates: Start Point: X.5,Y1 Point A: X1.5,Y2 Point B: X2.5,Y2 Point C: X3.5,Y3 End Point: X5,Y3 Make sure to label the X and Y axes, the units and the coordinates.
11-11
2.
Using circular interpolation and absolute programming, draw an X,Y coordinate system and the tool path for these coordinates: Arc 1 Start point: X1,Y1 End point: X3,Y3 Center Point: X3,Y1 Arc 2 Start point: X3,Y3 End point: X5,Y5 Center Point: X3,Y5 Make sure to label the X and Y axes, the units and the coordinates.
3.
Does the tool move in a clockwise or counterclockwise direction for arc1?How about arc 2?

w w w w w w w Return all materials to their proper place at your lab station. Return the machine to the home position. Complete the Inventory Checklist for your station. Select Exit from the File menu to exit the control program. Shut off the Benchtop Router and the controller box. Select Shut Down from the Start menu on the computer Shut off the computer
11-12
Academics
Vocabulary Axis - The reference line of a coordinate system (axes, pl.). Parallel - Two or more straight lines or planes, that remain an equal distance from each other at all points and do not cross. Perpendicular - A line or plane at a right angle to a given line or plane. Point of Origin - The intersection where axes meet with a value of zero on each axis. Quadrant - One quarter of a plane divided by two axes. Three-Dimensional Coordinate System - A coordinate system based on three axes: X, Y and Z. Two-Dimensional Coordinate System - A coordinate system based on two axes: X and Y. Units - The divisions of a coordinate system (for example, inches or millimeters). Absolute Programming Mode - An NC programming mode that specifies tool motion from the point of origin (0,0). Incremental Programming Mode - An NC programming mode that specifies tool motion from the last tool position. Arc - Any portion of a circle. Circular Interpolation - Interpolation used to cut circles or arcs, specified by the beginning and ending points of the arc, the center of the circle and the direction of the cut. Interpolation - Movement from one coordinate point to another along a defined tool path at a programmed rate of speed. Linear Interpolation - Interpolation using straight-line motions between coordinate points, the end point of one line segment being the start point of the next line segment.
11-13
11-14
Activity 12
Developing an NC Program
OBJECTIVES In this activity you will accomplish the following: w w w w w w SKILLS In this activity you will develop the following skills: w w w w w w w w MATERIALS In this activity you will need the following materials: w w w Benchtop Router Computer with the BenchRouter Control Program installed Worksheets for this activity Technology: Systems: Resources: Interpersonal: Information: Basic: Thinking: Personal: Create a Computer program Use a system Manage time Participate as a member of a team Acquire / evaluate information Reading and writing Learning Responsibility and self-management Develop an NC part program from a part drawing. Create a part drawing Plot the coordinates for the sample part program provided (MAZE.NC), Determine the cutting sequence, Construct a program to machine the part Enter the program in the provided coding sheet.
12-1
OVERVIEW Now that you understand how to create NC words and use those words together to form blocks of code, you can use that knowledge to write an NC part program. There are several steps involved in writing an NC program: 1. Sketch the part. 2. Draw the part to scale on graph paper. 3. Determine the stock size and select the tool. 4. Determine the feed rate and depth of cut. 5. Determine how to cut the part. 6. Enter the code on a coding sheet. Each of these steps must be performed before you can enter the code into the computer. The tasks covered in the ABAR.NC program shown here are examples only. You will not be performing these tasks. Later in this section you will be asked to create an NC program of your own, called Maze.NC. PROCEDURES

Task 12-2 Sketch the Part

Your first task is to sketch the part you would like to machine. Sketching the part gives you your first idea of what the part will look like. This is when you should begin to consider the size, or the dimensions of the part. You will also decide what material youll make the part from, and how youll cut it. (If you were working from a machinists drawing, a sketch would not be necessary.) w Create a sketch of the part according to the requirements posted.
2.000 1.300 1.000 .700
3.000
2.500 1.600 1.000 .700
.500 .500 1.500
12-2
Task 12-3 Draw the Part to Scale on Graph Paper

Once you have a visual idea of the part youd like to make, you have to draw the part to scale on graph paper. The scale is the size of the drawn part compared to the size of the actual part. The part shown in this drawing is scaled up (drawn larger than actual size). You should use the actual size or scale the drawing up so each detail is easier to see.
3.3 3.2 3.1 3.0 2.9 2.8 2.7 2.6 2.5 2.4 2.3 2.2 2.1 2.0 1.9 1.8 1.7 1.6 1.5 1.4 1.3 1.2 1.1 1.0 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 2.1 2.2 2.3
(1.000,2.500)
(.700,1.600)
(1.300,1.600)
(.500,1.000)
(1.5,1.000)
(.500,.700) (.500,.600) (.500,.500)
(1.5,.700) (1.5,.600) (1.5,.500)
w w
The drawing should show the outline of the workpiece plus a representation of the finished part. Next, you should plot, or locate, the part's coordinates. The coordinates must be precise so you know the parts exact size. Because they are easier to calculate, it's best to use decimals instead of fractions to plot the coordinates; for instance, use .5 instead of 1/2. Since the workpiece is placed on the table with the longest side along the X axis, the part is drawn in the same manner.
Task 12-4 Determine the Stock Size and Select the Tool
w When choosing the stock for a part, always try to use the smallest piece possible to eliminate waste. For the sample part stock, choose a piece of wood (pine is fine) with a total size of 3 x 2 x 1.5. When selecting the cutting tool to use for machining a part, consider the profile of the surface you want. Different kinds of bits produce different surfaces. For example, use center-cutting end mills to cut flat surfaces and start cavities, and ball shaped end mills to cut curved surfaces. After selecting a tool type, the tool size must be determined. As a general suggestion, select the largest size available of an appropriate tool; large tools can remove more material than small tools can in the same period of time. For this sample part, choose a 0.125 diameter center-cutting end mill.
Task 12-5 Determine the Feed Rate and Depth of Cut

w The feed rate depends on the stock material. The ABAR part was designed to be machined from machinable wax. The maximum recommended feed rate for machinable wax is no more than 9 ipm (inches per minute). However, you will use a feed rate of 6 ipm to cut the sample part. If the part had been designed to be machined from a harder material, like steel, you would use a slower feed rate, perhaps 1 ipm. The depth of cut depends on the tool size and the type of material being machined. The depth of cut for machinable wax should be no more than .2 inches deep. For the sample part, choose to make the cuts at a depth of .02 inch (-.02 on the Z axis). You should be able to find the feed rate, spindle speed and depth of cut information you need in the following table.
The table will help you determine approximate maximum values for feed rates, spindle speeds and depth of cut for different materials and tool diameters on the Benchtop Router. Experience and experimentation will help you to choose the best values for your particular needs.
Material 1/8" Feed Speed Depth Acrylic Aluminum Brass Delrin Wax Steel
Tool Diameter 3/16" Feed Speed Depth 6 2.5 3.5 5 9 .7 2000 2000 2000 2000 2000 1000
12-4
1/4" Feed 6 2 3 5 9 .5 Speed Depth 2000 2000 2000 2000 2000 750 .125 .03 .03 .1 .2 .015
6 3 4 5 9 1
2000 2000 2000 2000 2000 1500
.06 .03 .03 .1 .2 .015
.01 .03 .03 .1 .2 .015
Task 12-5 Determine How to Cut the Part

Before you can write the NC code, you must determine how you will go about cutting the part. This is a very logical process. You simply map-out each action of the cutter by deciding where to start cutting, where to insert the tool, where to extract the tool, when to move to a new cutting position, and so on. When you have finished mapping out this sequence, it will be very easy to translate the information into NC code. The following example shows how the cutting sequence for the ABAR.NC program planned; the Acontour was cut first and the bar-shaped pocket second.
Cut the A-Contour

1. 2. 3. 4. The cutter moves to the Start Point. The cutter makes a rapid traverse movement above the workpiece, not touching the workpiece. When the cutter reaches the correct X and Y coordinates above point A (X1,Y.5), the spindle turns on. The cutter is inserted into the workpiece at point A to the depth (Z-.02) we decided on earlier. The cutter moves according to the coordinates on the scaled drawing. It moves up the leading edge of the A-contour to point B (X2.5,Y1), then down the trailing edge to point C (X1,Y1.5). The cutter lifts out of the workpiece (Z.1). The cutter moves to the next insertion point. The cutter makes a rapid traverse move to the X and Y coordinates of point D (X1.6,Y1.3). The cutter is inserted into the workpiece (Z-.02) to the same depth as before. The cutter moves to point E (X1.6,Y.7). The cutter lifts out of the workpiece (Z.1).
5. 6. 7. 8. 9.
10. The cutter moves to point F (X.7,Y1.5). Point F is the start point for the barpocket.
B D
C E
Tool Path:
Approximate tool start position (0,0) Student Activities Book 9712 12-5
Cutting Rapid Traverse
Cut the Bar-Pocket

1. 2. The cutter is inserted at point G (Z-.02). The outline of the pocket is cut. The cutter moves from point G (X.7,Y1.5) to points H (X.5,Y1.5), J (X.5,Y.5), K (X.7,Y.5) and back to G.
F G H
K
3. 4. 5. 6.
The cutter moves to point L (X.6,Y1.5). The cutter moves to point M (X.6,Y.5), removing the center of the pocket. The cutter lifts out of the workpiece (Z.1). The cutter returns to the original start point and the spindle is turned off. The program ends here.
G L
Original tool start position (0,0)
Task 12-7 Enter the Code on a Coding Sheet

Now that we have the information necessary to machine the part (the stock size, the part coordinates, the feed rate, the cutting sequence), we can use this information to create the NC program codes and write the codes on an NC coding sheet.
12-6
An NC coding sheet is a simple form for writing NC code. After the code is written on this sheet, it is used as a guide for entering the code into the computer. The instructions on the coding sheet should be in this order: 1. 2. 3. 4. 5. 6. 7. Move the tool to its starting position. Specify the programming mode (absolute or incremental). Turn on the spindle. Specify the feed rate. Perform each cut and rapid traverse motion according to the cutting sequence and coordinates on the graph paper drawing. Return the tool to the starting position. Turn the spindle off.
The coding sheet for the ABAR.NC program is shown on the next page. All of the necessary address characters are given as column headings. Each parameter is placed under its appropriate heading. For example, the first block in the program has a zero under the N heading, the numbers zero and 90 under the G heading, and a value of .1 under the Z heading. The comment Rapid, Absolute, To Z Start Point is under the Comments heading as a reminder of what we want this block of NC code to do. So, the first block of NC code reads:
N0G0G90Z.1;MOVE TOOL AWAY FROM STOCK
When writing an NC program, there are a few things to remember: w w w w w To make a strictly horizontal movement with the tool, place the X or Y coordinate in a block separate from the Z coordinate. To make a strictly vertical movement with the tool, place the Z coordinate in a block separate from the X and Y coordinates. To move the tool in a diagonal line, place both the X and Y coordinates in the same block. To make rapid traverse movements, the cutter must first move in the +Z direction, away from the workpiece. Before cutting, the spindle is turned on and the cutter is inserted into the workpiece in the -Z direction.
Remember: It is very important to remember the positive and negative Z axis directions and to be aware of the tool's position at all times when machining. If the Z coordinates in your program are incorrect, the cutter could plunge into the workpiece, possibly breaking the cutter and damaging the workpiece as well.
12-7
12-8
CREATE Y OUR O WN NC PROGRAM
Task 12-8 Create MAZE.NC

Now that we've shown you how to create a part program, you can try writing one on your own. We've provided a part drawing with dimensions, a graph to plot the coordinates on, and a coding sheet. Your task is to transfer the drawing to graph paper, plot the coordinates, determine the cutting sequence and write the NC program. This is how the maze game will look after machining, but before cutting the excess off the ends. Notice how the axes relate to the game. Also, note where the point of origin is. Remember these things when you place the stock on the table. We've designed this maze to be cut from a 4.5 x 3 x 0.75 piece of stock using a 0.25 router bit. Milling the maze game is a two-step process. First, the top layer of material is removed and the recessed edge for the cover is made by cutting a pocket. Next, the maze (the ball run) is cut. w w w w Use the graph provided with the worksheets to draw the part shown. Your first task will be to pocket out the recessed area where the cover will fit in. Your second task will be to cut the ball run. You may wish to begin by placing a small dot at each of the four corners and writing in the coordinates. When you plan the sequence for each cut, dont forget to include the Z axis moves; when to insert and when to extract the cutter. Your next task is to enter your NC code on an NC coding sheet. Use the NC coding sheets that are part of the Activity Worksheets. Do not write in this book. When you fill in the NC coding sheet, dont forget to turn the spindle on and off and set the feed rate.
Cut 1/2 inch from both ends after milling.
0.5
00
(0,0)
+X
0.5
00
+Y
12-9
Material: The maze skill game can be made from a number of materials. Use whatever type of wood you have available. Although this part has a finished length of five inches, you should start out with a larger piece of stock. You should use a piece of stock six inches long, then cut off the excess when you are finished milling. When you clamp the stock to the to the hold down table, the clamp could get in the way of the cutter. With a larger piece of stock, the clamps are safely out of the way. The final dimensions of the stock will be 5 x 3 x 0.75. Tooling: To mill the game, use an 1/4 end mill. Initialization/Verification: Make sure to go into the Tool Library and define Tool 2 as a .25 carbide round nose bit. When setting the Graphics Parameters, set the Stock Size to X=5.0, Y=3.0 and Z=0.5. Running: Perform a safety check before the dry run and before actually cutting the part. Also, have your instructor check your set up before cutting the part. Finishing: When you finish cutting the game, use a fine sandpaper to remove any splinters and to smooth out the ball run. You may wish to coat the outside of the finished piece with polyurethane. Place a steel ball about the size of a bicycle bearing inside. The top of the game has a recessed edge. This edge is designed so you can place a clear cover over the top of the game. Use a piece of plexi-glass or acrylic (2.75 x 4.75 x .125 thick) for the cover. Youll have to round-off the edges of the cover to fit the inside corners of the recessed edge. Glue the cover into place.
12-10
0.375
0.25
0.25
0.375
5.0 4.75 0.25
3.0 2.75
0.25
0.125
0.25 0.5 min.
12-11
12-12
12-13

1. Put these steps in the correct sequence (16). a) b) c) d) e) f) 2. Determine stock and tool Enter NC code on coding sheet Determine feed and depth of cut Sketch the part Determine cutting sequence Draw the part to scale _____ _____ _____ _____ _____ _____
Greater feed rates and depths of cut can be specified when cutting softer materials like: a) b) c) Steel Machinable wax Aluminum
3.
If the top of the workpiece is established as Z = zero, then cutting into the workpiece represents a: a) b) c) Negative Z value Positive Z value Either positive or negative Z value
4.
Stock size should be: a) b) c) As large as possible As small as possible Any size, as long as it fits in the Benchtop Router
5.
When cutting a flat surface, which type of end mill should be used: a) b) c) Any end mill available Ball end mill Flat, center-cutting end mill

w w w w w w
Return all materials to their proper place at your lab station. Return the Router to the Home position. Complete the Inventory Checklist for your station. Select Exit from the File menu to exit the control program. Shut off the router and the controller box. Select Shut Down from the Start Menu on the computer.
Activity 13
Editing Your NC Program

OBJECTIVES In this activity you will: w w w w SKILLS In this activity you will develop the following skills: w w w w w w w w MATERIALS For this activity you will need the following materials: w w w This Manual The computer and control program Coding sheets from the previous activity Technology: Systems: Resources: Interpersonal: Information: Basic: Thinking: Personal: Use and Maintain equipment and computer programs Understand Computer systems and programs Manage time Participate as a member of a team Acquire / evaluate information Reading and writing Learning Responsibility and self-management Run the Control Program Enter the sample NC program you wrote into the computer Save the program Edit the program
13-1
OVERVIEW Now that you have written an NC part program, you will enter it into the computer and edit it, if necessary. After entering your part program into the computer, you must save the program, and if there are any noticeable mistakes in the program, correct them. PROCEDURES


13-2
Task 13-3 Create the File

w w Select New from the File menu, or click on the New File button on the Standard toolbar. An Untitled file appears. Using your coding sheet and the keyboard, type your NC program into the untitled window.
13-3
Task 13-4 Save the File

w w It is a good idea to save your program as you go along. After you enter a few lines of code, select Save from the File menu. The Save As dialog box appears. In the title box, type the name of your file. As a suggestion, you may want to use Maze, which describes what the part will look like when you are done. It is also a good idea to keep file names as short as possible. You do not need to type the .nc extension after the file name. The program will add it automatically. After naming the file, select the directory to save it in. The default directory is the BenchRouter folder, but you may wish to save it elsewhere. Just click the mouse in the Save In window to get a directory of file folders. Choose the folder to store the file in and then click on the Save button. Return to the file Edit window and continue entering the code. When you are finished, save the file again by choosing Save from the File menu.
w w
Task 13-5 Edit Your NC Program

When you entered your NC program, you may have made some typing errors (It happens to the best of us). Check each block of your NC program carefully to make sure it matches the coding sheet. When you have finished editing, dont forget to save your program again! Remember: Always save your NC program before verifying or running the program on the Benchtop Router.
13-4
Common Programming Errors

Some common programming errors include: w w w w Using the letter O instead of the number zero. Usually, zeroes on a computer are narrower than the letter O, so check each one to make sure its a zero. Using the letters l or I instead of the number one. Check each 1 to make sure its the number one. Entering the wrong number or adding an extra digit to a number. Its easy to miss a number error, so check carefully. Forgetting to switch back to linear interpolation (G01) after using rapid traverse (G00).
13-5

Q Q 1. What types of problems did you run into writing your NC program? What do you think would be the result of improper coding in an NC program? After editing a part program, the program remains in the computer: a) b) c) 2. 3. Forever Until the program is deleted Until the computer is turned off, unless you save the program
List two (2) mistakes that commonly occur when entering a part program. When entering a part program, the address characters must be typed as: a) b) c) Upper-case letters Lower-case letters Upper- and/or lower-case letters
4.
Before adding a comment to a line of NC Code, type a: a) b) c) d) Space Semicolon Comma None of the above
5.
Complete the following sentences. a) b) An address character together with its parameter is called a _________. A line of NC code is called a _________.

w w w w w w w Return all materials to their proper place at your lab station. Return the router to the Home position. Complete the Inventory Checklist for your station. Select Exit from the File menu to exit the control program. Shut off the Benchtop Router and the controller box. Select Shut Down from the Start Menu on the computer. Shut off the computer.
13-6
Activity 14
Verify and Run Your Program

OBJECTIVES In this activity you will accomplish the following: w w SKILLS In this Activity you will develop the following skills: w w w w w w w w MATERIALS In this activity you will need the following materials: w w w w w w Benchtop Router Computer with the BenchRouter Control Program installed Worksheets for this activity Workpiece Clamps NC program Technology: Systems: Resources: Interpersonal: Information: Basic: Thinking: Personal: Machine a part Utilize an entire CNC system Manage time Participate as a member of a team Aquire / evaluate information Reading and writing Learning Responsibility and self-management Verify and dry run your NC program Run your NC program
14-1
OVERVIEW In this activity you will be using procedures you learned in previous activities. With that experience behind you, things should go a little faster. This time you will be running the program that you wrote. Safety is still the most important factor, so be sure all the safety guidelines are followed. Good luck! PROCEDURES

w w w Check that all materials required for this activity are available at your lab station. Verify that your lab station passes all the safety guidelines. Complete the inventory and safety checklists on the worksheet for this activity.
Task 14-2 Power up the Benchtop Router

Task 14-3 Set Machine Home

w w From the Setup Menu, select Set/Check Home. When the dialog box appears, click on Home.
Task 14-4 Open Your NC File

w w Select the Open command from the File menu, or click on the Open button on the Standard toolbar. The Open dialog box appears. The dialog box will display the BenchRouter folder, which contains a number of programs. If your program was saved here, double click on the filename, or click on the filename and then click on the Open button. If your file was saved to another folder, you will need to navigate to that folder to open your file. The Edit window will appear with your NC program displayed.
w w
14-2
Task 14-5 Set Parameters

To adjust the settings you first need to open the Verify setup dialog box. Do any one of the following: w w w w Double click on the Verify window; Select the Program Menu and choose Verify from the pull down menu, or; Select Verify from the Standard Toolbar and choose Verify Settings. The Verify Setup dialog box appears.
Adjust the View

1. 2. 3. Select View. Select either Solid or Centerline (for a solid or a centerline representation of the tool and workpiece). Select Isometric for a three dimensional view of the part.
14-3
Adjust the Stock

1. 2. 3. 4. 5. Select the Stock tab. Enter the Stock Dimensions for the Maze.NC program. The stock dimensions are X=5, Y=3 and Z=.75. Set the Initial Tool Position to X=0, Y=0 and Z=1 Set the point of Origin to zero on all three axes. Select OK. The dialog box will close, and you should notice a change in the shape of the workpiece in the Verify Window.
Select the Tool for Verification

You should have specified the tool to be used in your nc program. If it was something other than an.125 bit , you will need to define the tool before selecting it. If it is a .125 bit, select it from the tool library. 1. 2. 3. 4. Select Tool from the Tools Menu. The Select Tool for Use dialog box appears. Select Tool 1 from the pull-down list. Click on the Select Tool button. Select Save from the File menu to save all your settings.
14-4
Task 14-6 Verify the Program

Tool path verification allows you to check for programming errors. It also gives you a chance to see a picture of the part being cut, without actually running the Router. 1. Select Verify from the Program Menu or from the Standard Tool Bar. The Verify Program dialog box appears. The default starting line for the program is Line 1. When verifying a program, you should always begin on Line 1. Click on the Verify Program button, then watch the Verify Window. You will see the NC program executed on the graphic workpiece.
2.
If there are any problems, the message bar at the top of the screen will turn red, and a message will appear in the middle of the screen. Q Q Did your program run through verification without any problems? If not, what were the problems? How did you fix them?
Task 14-7 Dry Run the NC Program

This will give you the chance to see if all the movements of the Benchtop Router make sense, and that the tool is in no danger of striking any fixtures or crashing into the table. Although the dry run is performed with no stock mounted, you will need to set the point of origin using the workpiece. After you have done that, you will remove it. Begin with the Emergency Stop button pressed in, and the spindle speed turned all the way down. The clamps should be mounted on the hold down table. 1. 2. Mount the workpiece in the vise. Mount the tool in the spindle. Remember to leave the brush off of the spindle head so you can see the tool. Close the Safety Shield and pull out the Emergency Stop button. Select Jog Control from the View Menu (or the Standard Toolbar). The Jog Keypad appears. Use the Jog Keypad to jog the tool to the top of the front left corner of the workpiece. Select Set Position from the Setup Menu. The Set Position dialog box appears. Enter zero in the X, Y and Z boxes. Click on OK. The values in the Position Readout all change to zero. Jog the tool up and away from the workpiece. Press the Emergency Stop button, open the Safety Shield and remove the workpiece. Return the Safety Shield to the closed position and pull out the Emergency Stop button.
3. 4. 5. 6. 7. 8. 9.
10. Put on a pair of safety glasses and complete the Safety Checklist. 11. Select Run/Continue from the Programs Menu. The Run Program dialog box appears.
Student Activities Book 9712 14-5 CNC Technology: Benchtop CNC Router
12. Click on the Run Program button. As the part program runs, watch the tool motion in relation to the clamps (and eventually the workpiece). Look for signs of a possible tool crash and be prepared to press the Emergency Stop button on the Benchtop Router. Q Do you get any error messages while the program is running? How would you correct them if you did?
If you had to edit the program at all, be sure to save your changes before you exit the program.

1. Jog the tool to position the center of the tool tip at the top of the front, left corner of the workpiece. Jog until the tip of the end mill touches the surface of the workpiece. Select the Set Position command from the Setup Menu and enter zero for all three axes. Replace the brush around the spindle head.
+Z
2.
Tool
+Y
(0,0,0)
Point of Origin
+X
Task 14-9 Verify all Settings

1. 2. From the tools menu, choose Select Tool and verify the correct tool is selected. Select the Operator Panel and check that the spindle speed is set to 100%.
14-6
Task 14-10 Run the Program

Before executing your NC program, check that all safety precautions have been taken. The safety shield should be closed, and you should be wearing safety glasses. If anything goes wrong, immediately press the Emergency Stop button on the Benchtop Router to stop the operation. To run the program: 1. 2. After reviewing the Safety Checklist, select the Run/Continue command from the Program Menu. The Run Program dialog box appears. Make sure that the Start Line box is set to line 1 of the program.
3. 4.
Click on the Run Settings button. The Run Settings dialog box appears. Make desired changes in the Run Settings dialog box, then select OK.
5. 6.
Click on the Run Program button to begin running your program. After the part is machined, press the Emergency Stop button before opening the safety shield and removing the finished part.
14-7

Q Why do you think it is so important to verify the NC program in different ways before actually cutting the part? What are some of the dangers of just running the program?

w w w w w w w Return all materials to their proper place at your lab station. Return the router to the home position. Complete the Inventory Checklist for your station. Select Exit from the File menu to exit the control program. Shut off the Benchtop Router and the controller box. Select Shut Down from the Start Menu on the computer. Shut off the computer.
14-8
Activity 15
Conclusion
OBJECTIVES In this activity you will: w w w SKILLS In this activity you will develop the following skills: w w w w w w w w MATERIALS For this activity you will need the following materials: w w w w w w This Manual The Benchtop Router The computer and control program Graph paper NC coding sheets Your imagination Technology: Systems: Resources: Interpersonal: Information: Basic: Thinking: Personal: Apply the learned technology to a task Utilize all the parts of the system Manage time Participate as a member of a team Aquire / evaluate information Reading and writing Learning Responsibility and self-management Measure your knowledge of NC programming and mill operation Design and create an NC program for a part of your own Time permitting, machine that part.
15-1
OVERVIEW This activity concludes the Benchtop Router Teklink. The test you will now take will measure your knowledge and skills with the Benchtop Router. Take the test according to your teachers instructions. Allow 30 minutes for the test. When you have completed the test, return it to your instructor. PROCEDURES
Task 15-1 Final Project

Using the your new CNC programming skills and the Benchtop Router, design and cut a small sign (4.5 x 10 max) with your school initials on it. Run a small border around the lettering for decoration, if you want. Below are some examples of what your sign might look like. Remember to leave enough room on each end for the clamps to hold the stock on the table, and to keep your design simple. Create a part drawing, and an NC program to machine your part. Use the graph paper and coding sheets provided in the activity worksheets. Don't forget to include tooling specifications, stock size and stock type. If time permits, you may be able to verify and run your program on the Benchtop Router. Good luck. 1. 2. Stock size is 4.5 x 10 (max) x .75. Use a .25 router bit to make the cuts. Letters are 2 tall and outline is 3x 6.5. Both are centered on the stock
Steps for writng the program: 1. 2. 3. 4. 5. 6. Sketch the part. Draw the part to scale on graph paper. Determine the stock size and select the tool. Determine the feed rate and depth of cut. Determine how to cut the part. Enter the code on a coding sheet.
15-2
Mudville Technical High School
This drawing has been scaled by half.
15-3
15-4

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CNC Router

CNC Technology: Benchtop CNC Router

Student Activities Book

Student Activities Book

1997 Light Machines Corporation and Intelitek

Manchester, NH, U.S.A.

December, 1997 34-7535-0000

1997 Light Machines Corporation All Rights Reserved.

The Control Program

Student Activities Book 9712

CNC Technology: Benchtop CNC Router

Mounting the Stock

Verify and Dry Run the Program

Student Activites Book 9712

CNC Technology: Benchtop CNC Router

Run the NC Program

Student Activities Book 9712

CNC Technology: Benchtop CNC Router

Editing Your NC Program

Verify and Run Your Program

Student Activites Book 9712

CNC Technology: Benchtop CNC Router

About the Teklink Activities Book

Student Activities Book 9712

CNC Technology: Benchtop CNC Router

Student Activites Book 9712

CNC Technology: Benchtop CNC Router

Student Activities Book 9712

CNC Technology: Benchtop CNC Router

Student Activities Book 9712

CNC Technology: Benchtop CNC Router

Student Activities Book 9712

CNC Technology: Benchtop CNC Router

Student Activities Book 9712

CNC Technology: Benchtop CNC Router

Student Activities Book 9712

CNC Technology: Benchtop CNC Router

Student Activities Book 9712

CNC Technology: Benchtop CNC Router

Emergency Stop Button

Student Activities Book 9712

CNC Technology: Benchtop CNC Router

Task 1-1 Safety Test

Student Activities Book 9712

CNC Technology: Benchtop CNC Router

Student Activities Book 9712

CNC Technology: Benchtop CNC Router

Student Activites Book 9712

CNC Technology: Benchtop CNC Router

Spindle Speed Control

Student Activities Book 9712

CNC Technology: Benchtop CNC Router

WARNING! DO NOT OPEN NO USER SERVICEABLE PARTS INSIDE

Student Activites Book 9712

CNC Technology: Benchtop CNC Router

Student Activities Book 9712

CNC Technology: Benchtop CNC Router

Task 2-1 Inventory and Safety Checks

Task 2-2 Identify Router Components

Emergency Stop Button

Student Activites Book 9712

CNC Technology: Benchtop CNC Router