# CNC Mill 1

Source: https://wisconsin.twango.dev/des-inv/cnc/cnc-1

# CNC Mill 1

Instructions for completing the machine portion of the CNC Mill 1 upgrade.

## Overview

These lab instructions are for the CNC Mill 1 upgrade. If at any point during the training you have any questions please contact staff.

## Machine Guides

- [Eisen Mill Guide](https://kb.wisc.edu/engr/teamlab/123365)

## Material Requirements

Parts A & B will be made on the same piece of HDPE stock (one on top face, one on bottom face). The material will be given to you when you arrive for your Mill reservation. You will also be given a sharpie marker in a holder that is used for the trial run to verify your part.

Tools: All necessary tools will be located in the yellow toolbox by the Mill.

## Parts

### Part A

> See [[cnc-mill-1a]] for the full engineering drawing.

**Tool list:**

- 3/8" Diameter 2-Flute center cutting end mill
- 3/8" Spot drill
- 1/4" Drill bit
- Keyless drill chuck
- 1-1/2" Parallels
- Edge finder
- 3/8" Collet
- Deburring tool — Swivel Type
- 6" Rule
- 6" Caliper

### Part B

> See [[cnc-mill-1b]] for the full engineering drawing.

**Tool list:**

- 1/4" Diameter 2-Flute center cutting end mill
- 1-1/2" Parallels
- Edge finder
- 3/8" Collet
- Deburring tool — Swivel Type
- 6" Rule
- 6" Caliper

## Terminology

### X, Y, Plus (+), Minus (-)

The ProtoTRAK EMX works in the Cartesian coordinate system. This is the common number line system that you can use to plot the location of a point in two dimensions, X and Y. Any given point may be located exactly by plotting its position on the X and Y axes.

For example, point A below is at point X = 2, Y = 1, or (2, 1).

![[cnc-1-fig02.png]]

The point where the X line and the Y line cross is the (0, 0) point. This is known as Absolute 0.

- To the right of Absolute 0 is X plus; to the left is X minus.
- Above Absolute 0 is Y plus; below is Y minus.

### Absolute (ABS) and Incremental (INC)

The **absolute dimension** is the point at which both X and Y are 0. Every part you make with a ProtoTRAK EMX will have an absolute zero that you give it. Put Absolute 0 where it will make it easy to define the other points you need to machine — a corner or the center of a circular pattern are usually best.

When you program, you tell the ProtoTRAK EMX what reference point the numbers use:

- **ABS SET** — absolute reference from (0, 0)
- **INC SET** — incremental reference from the previous point

#### Rules for Incremental Reference Positions

When the first dimensioned data in a new event is incremental, the ProtoTRAK looks at the previous event's ending point:

| Event type | INC reference from |
|---|---|
| DRILL | X, Y programmed in that event |
| BOLT HOLE | X CENTER, Y CENTER |
| MILL | X END, Y END |
| ARC | X END, Y END |
| CIRCLE POCKET or FRAME | First corner (X1, Y1) |
| REPEAT | Same as above, shifted by OFFSET |

### Tool Compensation

The ProtoTRAK lets you program the dimensions of the finished workpiece rather than the centerline of the tool. Tool cutter compensation (cutter comp) determines which side of the programmed path the tool cuts on.

![[cnc-1-fig01.png]]

Cutter comp is always specified as the tool being **right** or **left** of the workpiece while looking in the direction of tool motion.

> [!example] Tool Right
> ![[cnc-1-fig09.png]]

> [!example] Tool Left
> ![[cnc-1-fig10.png]]

**Tool center** means no compensation — the tool centerline moves to the programmed points.

### Conrad (Connecting or Corner Radius)

Conrad lets you blend two straight line segments with an arc without explicitly programming the arc.

![[cnc-1-fig03.png]]

Program a straight line from A to C, specify CONRAD = R, then program another straight line from C to E. The ProtoTRAK automatically blends the radius between them. For rectangular pockets or frames, CONRAD stands for corner radius.

## Operations

### Part A

#### Turn the ProtoTRAK EMX On

If the ProtoTRAK is idle for 20 minutes, the screen blanks (screen saver). Press any key or turn the X or Y hand wheels to wake it.

#### Screen Organization

Almost every screen has four sections:

![[cnc-1-fig05.png]]

| Section | Purpose |
|---|---|
| STATUS line (top) | Mode, inch/metric, servo on/off |
| INFORMATION area | Readouts, program listing, part graphics |
| CONVERSATION line | Data input prompts |
| SOFT KEY definitions | Five gray arrow keys on the right |

#### Keyboard Organization

Three sections:

- **SOFT KEYS** — five unlabeled keys on right; function defined by screen labels
- **DATA INPUT keys** — number keys and related; use ABS SET for absolute values, INC SET for incremental X/Y dimensions (either key works for non-position values)
- **MOTION CONTROL keys** — GO, STOP, and FEED (up/down arrows) upper right

#### Modes

Press the MODE function key to see the mode select screen:

![[cnc-1-fig07.png]]

Press the soft key next to the mode you want.

#### Manual Operation

From Select Mode, press the DRO soft key:

![[cnc-1-fig06.png]]

1. Press X, ABS SET, Y, ABS SET, X INC SET, Y, INC SET — zeros absolute and incremental readouts.
2. Press INC/ABS to toggle between readout modes.
3. Crank X hand wheel to move table left to X 1.0000 INC.
4. Crank Y hand wheel to move saddle away to Y -1.0000 INC.
5. Press X, INC SET and Y, INC SET to reset incremental to zero.
6. Move X another inch to 1.0000 INC and Y another inch to -1.0000 INC.
7. Press INC/ABS to show absolute: X should read 2.0000 ABS, Y -2.0000 ABS.
8. Press X, ABS SET, Y, ABS SET to reset absolute to current position.

#### JOG

> [!warning]
> Never operate the ProtoTRAK under servo motor control unless the handles are folded into their safety position.

1. Fold up the X and Y hand wheels (pull out, then fold in).
2. Press the JOG soft key. Conversation line says "Feed rate 100" (100 ipm in INCH mode).
3. Press and hold X to move table left; release to stop.
4. Press and hold Y to move table toward you; release.
5. Press `/–` to change to "Feed rate -100".
6. Press and hold X to move table right; Y to move saddle away.
7. Press DOWN arrow to decrease speed; UP arrow to increase.
8. Press a number key then ABS SET to set feed rate as a percentage (e.g., 9 → 9% = 9 ipm).
9. Press RETURN soft key to exit Jog and return to manual.

#### Return to Absolute Zero

> [!warning]
> The following will cause the machine to rapidly move under CNC control.

1. Ensure the spindle is clear of the top of the vise/part.
2. Make sure the readout shows ABS. If not, press INC/ABS.
3. Move hand wheels to confirm you're not at zero.
4. Press RETURN ABS 0 soft key.
5. Press GO — the table and saddle will automatically move to the absolute zero set earlier.

#### Teach

Teach allows you to machine a part by hand and have the ProtoTRAK remember the tool positions for later repeats.

Example job (not the actual training material):

- Drill two 1/4" holes
- Mill a 1/4" slot

![[cnc-1-fig04.png]]

1. Set ABS 0 over the bottom left corner and position table near center of travel.
2. Press TEACH.
3. Press INC/ABS to get ABS readout.
4. Move table to X=1.0000, Y=1.0000. Press POSN DRILL.
5. Move to X=2.0000, Y=1.0000. Press POSN DRILL.
6. Move to X=1.0000, Y=2.0000 (slot start). Press MILL BEGIN.
7. Move to X=2.0000, Y=2.0000 (slot end). Press MILL END.
8. Press END TEACH.
9. Press DELETE EVENT until TEACH POSN is Event 1.
10. Set TOOL # and TOOL DIA to defaults (ABS SET).
11. For the mill event: set TOOL OFFSET to 0 (CENTER), feed rate to 6, TOOL # to 2.
12. Press MODE → RUN → START → GO to run the program.

### Program Strategy

Part A programming strategy:

1. Set lower-left corner as Absolute 0.
2. Drill leftmost hole using a Position Drill Event.
3. Drill next 3 holes using a Repeat Event.
4. Drill the 8-hole bolt circle using a Bolt Hole Event.
5. Mill the upper-left diagonal using a Mill Event.
6. Mill the lower-left arc using an Arc Event.
7. Mill the circular pocket using a Pocket Frame Event.
8. Mill the rectangle profile using a Pocket Frame Event.

### Making and Inputting the Program

#### Event 1 — Spot Drill the First Hole

1. Press MODE → PROG soft key.
2. At "Program Name" prompt: input `123`, SET.
3. Press POSN/DRILL → ONE.
4. "X END" → `2.75`, ABS SET.
5. "Y END" → `.75`, ABS SET.
6. "TOOL #" → `1`, ABS SET.
7. "Tool Dia" → ABS SET (spot drill diameter not critical).

#### Event 2 — The Next 3 Holes (Repeat)

1. Press SUB → REPEAT.
2. "First Event #" → `1`, ABS SET.
3. "Last Event #" → `1`, ABS SET.
4. "X Offset" → `.75`, INC SET (distance between holes).
5. "Y Offset" → `0`, INC SET.
6. "# Repeats" → `3`, ABS SET.
7. "Tool #" → `1`, ABS SET.
8. "Tool Dia." → ABS SET.

#### Event 3 — The Bolt Hole Pattern

1. Press POSN DRILL → BOLT HOLE.
2. "# Holes" → `8`, ABS SET.
3. "X CENTER" → `1.5`, ABS SET.
4. "Y CENTER" → `2.5`, ABS SET.
5. "Radius" → `1.`, ABS SET.
6. "Angle" → `90.`, ABS SET (first hole at top, counterclockwise from 3 o'clock).
7. "Tool #" → ABS SET (reuse last tool).
8. "Tool Dia." → ABS SET.

#### Event 4 — Sub Repeat to Drill All Holes

1. Press SUB → REPEAT.
2. "First Event #" → `1`, ABS SET.
3. "Last Event #" → `3`, ABS SET.
4. "X Offset" → `0`, INC SET.
5. "Y Offset" → `0`, INC SET.
6. "# Repeats" → `1`, ABS SET (use `2` to also countersink).
7. "Tool #" → `2`, ABS SET.
8. "Tool Dia." → `.25`, ABS SET.

#### Event 5 — Upper Left Diagonal

1. Press MILL.
2. "X Begin" → `0`, ABS SET.
3. "Y Begin" → `3.25`, ABS SET.
4. "X End" → `.5`, ABS SET.
5. "Y End" → `.75`, INC SET (or `4.0`, ABS SET — equivalent).
6. "CONRAD" → ABS SET (no blend).
7. "Tool Offset" → `2`, ABS SET (tool left of workpiece).
8. "Feed rate" → `5.`, ABS SET.
9. "Tool #" → `3`, ABS SET.
10. "Tool Dia." → `.375`, ABS SET.
11. "Continue" → `2`, ABS SET.

#### Event 6 — Lower Left Radius (Arc)

1. Press ARC.
2. "X Begin" → `0`, ABS SET.
3. "Y Begin" → `.5`, ABS SET.
4. "X End" → `.5`, ABS SET.
5. "Y End" → `0`, ABS SET.
6. "X Center" → `.5`, ABS SET (or `0`, INC SET).
7. "Y Center" → `.5`, ABS SET.
8. "CONRAD" → `0`, ABS SET.
9. "Direction" → `2`, ABS SET (counterclockwise).
10. "Tool Offset" → `1`, ABS SET (tool right of workpiece).
11. "Feed rate" → `5.`, ABS SET.
12. "Tool #" → `3`, ABS SET.
13. "Tool Dia." → `.375`, ABS SET.
14. "Continue" → `2`, ABS SET.

#### Event 7 — Circular Pocket

1. Press POCKET FRAME → CIRCLE PCKT.
2. "X Center" → `1.5`, ABS SET.
3. "Y Center" → `2.5`, ABS SET.
4. "Radius" → `.75`, ABS SET.
5. "Direction" → `2`, ABS SET (counterclockwise / climb milling).
6. "Fin Cut" → `.02`, ABS SET.
7. "Feed rate" → `8.`, ABS SET.
8. "Fin Feed rate" → `8.`, ABS SET.
9. "Tool #" → ABS SET.
10. "Tool Dia." → ABS SET.

#### Event 8 — Rectangle Profile

1. Press POCKET FRAME → RECT PROFILE.
2. "X1" → `3.75`, ABS SET.
3. "Y1" → `1.75`, ABS SET.
4. "X3" → `1.5`, INC SET (diagonal corner).
5. "Y3" → `1.25`, INC SET.
6. "CONRAD" → `.3`, ABS SET.
7. "Direction" → `2`, ABS SET (counterclockwise / climb milling).
8. "Tool Offset" → `2`, ABS SET (tool left on inside of rectangle).
9. "Fin Cut" → `.03`, ABS SET.
10. "Feed rate" → `5.`, ABS SET.
11. "Fin Feed rate" → `5.`, ABS SET.
12. "Tool #" → ABS SET.
13. "Tool Dia." → ABS SET.

#### Look at the Program

Press the LOOK hard key to see part graphics. The drawn part should look like this:

![drawn part](https://kb.wisc.edu/images/group362/83012/partconfirm.png)

The four pluses in the lower right may appear as squares on some software versions — that is normal.

#### Save the Program

1. Press MODE → PROG IN/OUT.
2. Enter a part number, press SAVE, wait for completion.

### Program Run Preparation

#### Setup the Workpiece

Place 1-1/2" parallels in the vise (one against each jaw, thin edge down). Place HDPE material on top of the parallels and tighten. The material should stick out to the left of the vise by about 1-1/2".

![[cnc-1-fig08.png]]

### Set up the Part Reference

1. Press MODE → DRO.
2. Press INC/ABS to show absolute (ABS).
3. Zero with X ABS SET and Y ABS SET.
4. Use the edge finder at 600–800 rpm to position the spindle center over the lower-left corner.
5. Readout should show X 0.0000 ABS and Y 0.0000 ABS.

### Program Run

> [!tip]
> Always do a trial run with a tool loaded ABOVE the vise/part to verify no collision. A Sharpie in a 3/8" collet can verify dimensions on plastic — lower the quill slowly to avoid damaging the tip. The LOOK function is not a reliable dimensional check.

#### Enter Run Mode

1. Press MODE → RUN → START.
2. Press GO — the saddle moves to the first hole location.

#### Spot Drill the Holes

1. "Load Tool 1" — load spot drill, start spindle, adjust RPM via [RPM calculator](https://kb.wisc.edu/engr/teamlab/page.php?id=82670).
2. Press GO to move to the first hole.
3. "Set Z" — lower quill until spot drill just touches; zero digital scale; spot drill to -0.040".
4. Shut off spindle; lower drill into hole bottom; lock quill; set quill stop.
5. Raise quill, start spindle.
6. Press GO to drill each remaining hole when prompted "Set Z".

#### Drill the Holes

1. "Load Tool 2 Dia .25" — load .25" drill in chuck, start spindle, adjust RPM.
2. Press GO; move to first hole.
3. "Set Z" — lower to contact, zero scale, drill to -0.125".
4. Lock quill; move quill stop up to drilled depth.
5. Raise quill, start spindle; press GO for each remaining hole.

#### Mill the Upper Left Diagonal

1. "Load Tool 3 Dia .375" — load 3/8" end mill; start spindle; adjust RPM.
2. Press GO — tool moves to upper-left diagonal start.
3. "Set Z" — bring tool to 1" above part; lock quill at stop. Raise table until cutter contacts part; zero Z DRO; raise to -0.125" ABS.
4. Press GO — tool cuts diagonal at 5 ipm.
5. "Check Z" — raise quill before rapid move.

#### Mill the Lower Left Radius

1. Press GO — rapid to arc start.
2. "Set Z" — lower to quill stop; lock quill.
3. Press GO — cuts arc at 5 ipm.
4. "Check Z" — raise quill.

#### Mill the Circular Pocket

1. Press GO — rapid to pocket center.
2. "Set Z" — lower to quill stop; lock quill.
3. Press GO — machines pocket at 8 ipm (rough + .020 finish cut).
4. "Check Z" — raise quill.

#### Mill the Rectangle

1. Press GO — rapid to rectangle start.
2. "Set Z" — lower to quill stop; lock quill.
3. Press GO — machines rectangle at 5 ipm with finish pass.
4. "Run Over" — part complete.
5. Press MODE to exit Run; regain manual control.
6. Remove part and deburr edges.
7. Show Part A to staff for evaluation.
8. If Part A passes, erase the program (see below).

### Part B

Make a program for Part B using the methods learned from Part A. Show finished Part B to staff. If Part B passes, erase the Part B program.

### Erasing the Program

1. Press MODE → PROG IN/OUT.
2. Enter the program number, press DELETE → .MX2 → YES.
3. Also delete all events: PROG → Go to Begin → delete each event until "Select an Event" appears.

## Next Steps

After completing [[cnc-1|CNC 1]], you can proceed to [[cnc-2|CNC 2]].