# CNC Mill 3

Source: https://wisconsin.twango.dev/des-inv/cnc/cnc-3

# CNC Mill 3

Lab instructions for the CNC Mill 3 upgrade on the TMC 7.

## Overview

These lab instructions are for the CNC Mill 3 TMC 7 upgrade, designed to be accompanied by the TRAK TMC 7 mill guide. If at any point you have questions, please contact staff.

## Machine Guides

- [TRAK TMC7 mill guide](https://kb.wisc.edu/engr/teamlab/internal/115531)

## Material Requirements

Aluminum stock — approximately 3" × 6" × 1" thick.

## Tool List

Students are required to set their own tooling. End mills are in the grey Hout box by the first aid station. All other tools are in the green tool box labeled TMC 7.

### Part A

> See [[cnc-mill-3a]] for the full engineering drawing.

**Setup:**

- Pair of 1-1/4" parallels with a 6" vise (see pro staff if unsure)
- Edge finder
- 8" caliper

**Tools:**

- Tool 1: 3/8" spot drill
- Tool 2: #7 drill (.201")
- Tool 3: 1/8" drill
- Tool 4: 5/16" 3-flute center cutting carbide end mill
- Tool 5: 3/32" 3-flute center cutting carbide end mill
- Tool 6: 1/2" 4-flute chamfer tool

### Part B

> See [[cnc-mill-3b]] for the full engineering drawing.

**Setup:**

- Pair of 1-1/4" parallels with a 6" vise
- Edge finder
- 8" caliper

**Tools:**

- Tool 1: 3/8" spot drill
- Tool 2: 5/32" drill (.156")
- Tool 3: 3/8" 4-flute carbide end mill
- Tool 4: 1/4" 4-flute center cutting carbide end mill
- Tool 5: 1/2" 4-flute chamfer tool

## Operations

### Part A

1. Refer to the [TRAK TMC 7 mill guide](https://kb.wisc.edu/engr/teamlab/internal/115531).
2. Use Enhanced ProtoTRAK Assistance (EPA) at any time.
3. Plug in the thumb drive and load `E:/programs/CNC Mill 3 Upgrades/M3-A1.CAM`.
4. Mount program tools in appropriate tool holders; place on tool cart in order. **Never use air blast without a tool in spindle.**
5. **Collet chuck:** ensure collet, nut, and holder are clean of chips, dirt, and coolant. Remove nut, push collet into nut until it clicks, screw nut back on, insert tool, tighten with designated spanner wrench until secure.
6. Set the reference (base) tool in the tool table.
7. Set Tool 1 in the tool table (same method as base tool).
8. Set Tool 1 in spot 1 of the ATC.
9. Repeat steps 6–8 until all tools are referenced in the tool table and in the ATC in order.
10. Secure stock in the vise; set X0, Y0 at center of stock using edge finder.
11. Use paper to set Z0 at top of stock. The tool used to set Z0 must be identified at the top of the DRO page.
12. Go to Set Up mode → press Verify Part.
13. Press Define Stock to enter part dimensions.
14. Press Make Part → Verify Part to preview the tool path.
15. Use TRAKing at the start of each operation to verify Z-axis offset for each tool.

### Part B

1. Refer to the [TRAK TMC 7 mill guide](https://kb.wisc.edu/engr/teamlab/internal/115531).
2. Use EPA at any time.
3. Plug in thumb drive and load `M3-B1.CAM` from the upgrades folder.
4. Mount tools and place on cart in order. **No air blast without tool in spindle.**
5. Same collet chuck cleaning and assembly procedure as Part A; tighten until secure.
6. Set reference (base) tool in tool table.
7. Set Tool 1 in tool table (same as base tool).
8. Set Tool 1 in spot 1 of the ATC.
9. Repeat steps 6–8 until all tools are referenced and in the ATC.
10. Secure stock; set X0, Y0 at center using edge finder.
11. Use paper to set Z0; verify tool ID on DRO page.
12. Set Up mode → Verify Part → Define Stock → Make Part → Verify Part.
13. Use TRAKing at start of each operation to verify Z-axis offset.

## Frequently Asked Questions

### What is TRAKing?

TRAKing lets you control X, Y, and Z feed using the hand wheels at the front of the machine. The right-side hand wheel is the coarse feed; the left hand wheel is the fine feed. Use TRAKing at the start of every tool change to verify Z offset is correct.

## Troubleshooting

### Why is my Z offset wrong?

The most common cause: Z offset was set with the wrong tool number. If you set Z offset with Tool 1, the DRO must show Tool 1. Users often set Tool 2 in the tool table and forget to switch the DRO back to Tool 1 before setting Z.

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> [!info] After this upgrade
> You do not need a CAM file or GCD file to run the TMC. The machine can be used manually and conversationally. Consider using this equipment after completing the upgrades.