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    THE MICROMILL DSLS 3000 (Digital Sync Lock Servo) Desktop CNC Machining System USER’S MANUAL Preliminary Release MicroProto Systems 2006

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    2 Table of Contents Introduction ……………………………………………………………………………… 3 Machine Setup ………………………………………………………………….………… 3 Installing the Axis Motors………………………………...

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    3 Introduction: Congratulations on your purchase of the MicroMill DSLS 3000 Desktop CNC machining system implementing advanced Digital Sync Lock Servo (DSLS) control technology. We feel you have obtained the best value in the market today with a machine that will provide you with years of pro...

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    4 2. To provide a shock absorption coupling for smooth acceleration and deceleration of the axis. When inserting the nylon tubes into the Lead Screw Collar it is essential that ALL 4 of them slide in freely without having to force or jam any of them in. This is tedious sometimes to get them al...

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    5 Fig. 3b - Locking the Coupling Tube in place with the Clamp Ring. Connecting the Step Motors to the Driver Box: The X, Y, Z, and A axis step motor connection ports are labeled on the back of the driver box as shown in figure 3c. The step motor cable Din 6 connectors are inserted into their re...

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    6 Connecting the Relay Control Module: The Spindle and Auxiliary Relay Control Module is connected to the I/O input port of the driver box and to a standard 120Vac outlet. The left 2 sockets are turned on with a standard M3 command and off with M5. The right 2 sockets are turned on with M8 an...

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    7 Assembling the Z-axis Column: The Z-axis column must next be aligned square with the table. In most cases this is a simple matter of using a standard machinist square set on the table and against the Headstock assembly as shown in figure 4 below. Rotate the column until the gap (indicated w...

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    8 Fig. 5 - Precise Squaring of the Column using a Dial Indicator This completes the initial mechanical setup of the MicroMill System. You are now ready to proceed onward with installing the software, jogging the axes around and then running the sample programs.

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    9 MICROPROTO MACH 3 CONTROL INTERFACE Operation Manual Kurt E. Daley, Ph.D. 2006 Introduction: The MicroProto Mach 3 program is a custom designed interface that executes universal G-Code programs and a lot more. The interface was designed with many full size CNC machining center features i...

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    10 Main Control Screen Fig. 5b – The main control screen showing all the various features. Figure 1 is a view of the main control screen showing all the various features the user has to work with. Each of the major screen features will be described in detail on the following pages.

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    11 Main Program Control Buttons Cycle Start This executes the current G-code program when pressed. The shortcut keys are Alt-R. Rewind This rewinds the current G-code program back to the beginning. The shortcut keys are Ctrl-W. Single BLK This activates single line program operation. When...

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    12 G-Code Program Display The G-code program display shows 10 program lines of code. The current line of code that is being executed is highlighted in white. The previous 5 lines of code and the next 4 lines of code are shown so the user can easily follow the program progress. When the...

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    13 stopped the user can click in the display box causing the entire box to become bright. From this point the user can scroll through the program code with the slide bar or mouse wheel. Simulate Program Run and Run From Here The Simulate Program Run button allows the user to quickly execut...

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    14 Program Limits The program limits display shows the minimum and maximum values for each axis that a part program will move to when executed. It is immediately displayed after the G-code program is loaded. 3D Graphic Part Display The graphic display shows the complete part geometry. T...

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    15 directly down on the part. During program execution the toolpath is drawn over the part geometry as a green line. Graphic Display Buttons The Display Mode button changes between different graphic display views. Pressing it toggles between the part limit view and machine limit view. Reg...

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    16 Cycle Jog Step Pressing this button cycles through the 10 preset jog increments that are defined in the Config – State section. The user can also click in the number display box and enter any desired jog increment number. Each axis will move this jog increment value when its jog key is pr...

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    17 This is the Feed Rate Override that displays the percent value used to scale the current Feed rate in the G-code program. The value is increased using the plus arrow to the left of the display while the negative arrow to the right of the display decreases it. The value can also be changed b...

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    18 Clicking the Reset button at any time disables the motor drive circuitry. The indicator above the Reset button will flash between red and green in this disabled state. If the Reset button is hit during a machine movement the motors are stopped instantly and the servos will most likely lose...

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    19 NEVER start a machining procedure until you have completely simulated or tested the expected motion and know exactly what the end result of the machining operation will be in general. Example Program # 1 (Engraving Text): This first example will demonstrate the simple use of the MicroMill fo...

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    20 9. Click in the Jog Rate box and enter 5 and then slow jog the tool bit down until it just touches the surface. 10. Click in the Z-axis Machine Tool Coordinate box and enter 0. This sets the surface of the material right at 0. 11. Click in the Jog Rate box and enter 100 to set it back ...

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    21 4. At this point it is a good idea to Dry Run the part before any cutting is done. This allows the user to verify that the motion looks right to prevent damage to the tool bit or work piece if something was not done right. 5. In the MDI line box enter G0Z1 to move the tool bit 1.0 inch abo...

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    22 Fig. 9 - Spindle set to top speed position. .NOTE: Once you become familiar with the machine and setting up the reference positions and so forth you may bypass the Preview and Dry Run steps and machine the part directly. The preceding process, though, is ALWAYS A GOOD IDEA when setting up...

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    23 Example Program # 3 (Drilling Holes): The next example shows the use of the MPS2003 program in drilling hole patterns using standard G83 peck drilling cycles. The following bolt hole pattern as displayed in figure 11 below will be generated. The program name is BOLTHOLE.TAP and contains 10...

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    24 Fig. 12 - Solid model representation of the finished 3D surface profile part FACEF.TAP. Machining Description: This example will consist of two machining operations being that of Roughing and Finishing. This requires a tool change and will, therefore, also demonstrate how to set a new to...

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    25 Roughing Operation: The first program file that will be executed is the Roughing Operation named FACER.TAP. The purpose of this roughing operation is to use a large diameter milling cutter to remove a large amount of material. This process leaves the part profile in a ‘Rough looking state...

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    26 CAUTION: Always wear your SAFETY GLASSES when inspecting a machining process up close. Chips can and will fly off randomly in all directions and will surely injure your eyes if they are unfortunate enough to be in the path of a chip projectile. Finishing Operation: Next the finishing opera...

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    27 G - CODES The following are all of the supported G-Codes used by the Mach 3 program. G00 Set all axis movement to rapid. Example: G00 X0.0Y0.0Z1.0 Rapid to the coordinate (0,0,1). G01 Linear interpolation movement at the specified feed rate F. Example: G01 X2.0Y2.0F10.0 Starting at (1,...

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    28 Start (0,0)End (2,0)I = 1J = 0Center(1,0) Fig. 16 - G02 Clockwise Circular Interpolation Move G03 Counter clockwise circular interpolation at the specified feed rate F. Example (Absolute Positioning Only): G02 X0.0Y0.0I-1.0J0.0F5.0 Center(1,0)End (0,0)I = -1J = 0Start (2,0) Fig. 16 - G0...

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    29 G20 Select INCH mode programming. All values encountered will be interpreted as distances in inches and feed rates as inches/minute. G21 Select metric mode programming. All values encountered will be interpreted as distances in mm and feed rates as mm/minute. G43 Tool Length Compensation ...

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    30 Material SurfaceR planeI planeG98G99Start Point of HoleZ DepthFeedrateMoveRapidMove Fig. 17 - G81 Drill Cycle Operation G83 Peck Drilling Cycle Description: The peck drilling cycle is a necessity anytime deep holes must be drill. Drilling a deep hole continuously to the hole depth would s...

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    31 Material SurfaceR plane12G99G98543Start Point of HoleZ DepthFeedrateMoveRapidMoveQDI planeQQ6 Fig. 18 - G83 Peck Drill Cycle Operation G90 Set absolute positioning mode G91 Set incremental positioning mode G92 Set new (X,Y,Z) reference position. Description: G92 X1.0Y1.0Z0.0 This sets ...

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    32 (0,0)(1,0)(1.5.1)(0.5,1) Fig. 19 - Machining multiple diamond inlays. M97 P100 G92 X-1.0Y0.0 M97 P100 G92 X-0.5Y-1.0 M97 P100 G92 X1.0Y0.0 M97 P100 G00 X-0.5Y-1.0 G92 X0.0Y0.0 M02 N100 G00G90X0.0Y0.0Z0.1 G01 Z-0.13 F10 X0.375Y0.75 X0.0Y1.50 X-0.375Y0.75 X0.0Y0.0 Z0.1 M99 G98 Return to...

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    33 G99 Return to R plane for drill cycles. M - Codes MO Program Stop. Upon reading an MO command the program stops and waits for the user to press C to continue program execution. M6 Tool Change. Upon reading an M6 command the program stops and waits for the user to press C to continue pro...

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    34 +X-X+Y-Y-Z+ZQuadrant1234+X-X+Y-YXY planeXYZ space Fig.20 - The Cartesian Coordinate System CNC MACHINE AXIS CONFIGURATION: +X-X+Y-Y+Z-ZSpindleMachine table Fig.21 - Machine axis system for 3 axis Vertical CNC Machine (Machine axis defined by spindle movement) Rotary Table or 4th Axis O...

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    35 The 4th Axis Rotary Table is mounted on the left side of the X-axis table as shown in fig. 22 below. The rotary table axis is specified with the letter A and is programmed in the same fashion as the X,Y and Z axes with all movements denoted in degrees. Positive rotations are in the CW direc...

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    36 PROBLEM: System does not work at all. CHECK: Fuse in back of unit (2A). PROBLEM: The motors don’t rotate at all when jogging. CHECK: If all the axis step motors don’t rotate and just vibrate when jogging most likely there is a problem with the PRINTER CABLE or PRINTER PORT of your ...

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    37 may be too tight. Under ideal conditions a single axis should achieve a maximum translation of 60 inch/min. Simultaneous two axis movement should also approach this, but may have to be a little slower. PROBLEM: Table is not moving what it is programmed to move. CHECK: You may have switched...

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    38 Fig. 23 - Checking Voltages inside the Electronic Driver Box. Shown are the range of voltages that will be present for a normally operating system. 3A In-line Fuse Low Voltage Capacitor 8 to 9 Volts DC High Voltage Capacitor 51 to 55 Volts DC

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    39 MACHINE MAINTENANCE Proper maintenance and care will assure that your MicroMill system will work at peak performance for many years of operation. Following the simple maintenance procedures below is all it takes to keep your machine in good running condition. Lubricating the Ways and Lea...

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    40 Backlash Measurement: The backlash of each axis can be measured by mounting a Dial Indicator to a secure base with the contact point against the moving member as shown in figure A3 below. Fig. A3 - Measuring the X-axis Backlash. The following procedure will determine the backlash for the...

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    41 Adjusting the Lead Screw Nuts: If your machine is running on a continuous basis and has accumulated many thousands of inches of travel on each axis throughout the years the Lead Screw Nuts may begin to show wear. This is evident if the backlash or play is larger then you think it should be....

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    42 Note: This can be a Very Tedious process and can really throw the whole Lead Screw/Nut system out of calibration ( Much Too Tight or Too Loose) if not done in the proper fashion. If you are not very experienced with ‘The Feel’ a properly adjusted machine should have it is recommended tha...

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    43 Fig. A5.2 - Brass Gib adjustment screws for the Saddle. Table Gib: The tapered brass gib on the table or X-axis is adjusted by the left side and right side Hex Screws shown in figure A5.3 below. Adjusting the left screw inward will tighten the table while adjusting the right screw inwa...

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    44 Adjusting the HeadStock: The Headstock is removed or re-positioned on the dovetail by loosening up the two Hex Screws shown in figure A6-A below. It is Very Important to NOT Over-Tighten these two screws when setting it back in place. Only a small tension is required to securely fasten the...

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    45 IMPORTING BOBCAD FILES Standard BobCad G-code files can be used by the MPS2003 program. The files must be post-processed with the following procedure and options in BobCad. 1. Generate a BobCad part drawing. 2. Enter the NC-Cam window. 3. In Setup make sure the following parameters are ...

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    46 The Digitizing Probe program MPSPROB3.EXE must be run and is entered with option E from the main menu. It has the following options. PROBE PROGRAM: 1 = DIGITIZE 2 = SET PARAMETERS 3 = EXIT OPTION 1 Start the digitizing process OPTION 2 Set the digitizing probe parameters DIGITIZING...

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    47 Set the Z axis sample distance to 0.0005 inches. X TEST DISTANCE = 0.01 Sets the distance the X axis advances between contacts to 0.01 inches. For method 2 this is both the X and Y increment test distance. X STORE DISTANCE = 0.05 Records the X,Y, and Z coordinates with the X resolution of ...

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    48 4. Enter the Probe Program and select 1 to start the digitizing process. You are prompted to start the digitizing at this point. Hit ENTER to begin or the SPACEBAR to escape. NOTE: Once option 1 is selected the filename is rewritten. 5. The digitizing process can be HALTED at any time...

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    49 Fig. D - Methods of digitizing a surface.

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    50 LEADSCREW COMPENSATION The leadscrew on the MicroMill system, like any other machine system, may have slight variations from the true pitch of the screw. The standard screw pitch is 20 turns/inch for all three axes on the machine. For the 1.8 deg/step drive motors and half stepping mode...

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    51 SPEEDS AND FEEDS FOR DRILLING DRILLING SPEEDS (HIGH SPEED STEEL DRILLS): Material Average Drill Speed (sfm) Magnesium Alaaa 300 s Aluminum 250 Brass and Bronze 200 Copper as 70 Cast Iron (soft) 120 Cast Iron (hard) 80 Mild Steel 110 Cast Steel 50 Alloy Steels (hard) 60 Tool Steel 60 Stain...

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    52 SPEEDS AND FEEDS FOR MILLING MILLING SPEEDS (HIGH SPEED STEEL END MILLS): Material Average Tool Speed (sfm) Magnesium Alaaa 300 s Aluminum 250 Brass and Bronze 150 Copper as 100 Cast Iron (soft) 80 Cast Iron (hard) 50 Mild Steel 90 Cast Steel 80 Alloy Steels (hard) 40 Tool Steel 50 Stainl...

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    53 MILLING FEEDS: TOOL FEED (inch/tooth) Material Face Mills Side Mills End Mills Magnesium 0.005 - 0.020 0.004 - 0.010 0.005 - 0.010 Aluminum 0.005 - 0.020 0.004 - 0.010 0.005 - 0.010 Brass and Bronze 0.004 - 0.020 0.004 - 0.010 0.005 - 0.010 Copper 0.004 - 0.010 0.004 - 0.007 0.004 - 0....

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