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Milling Machine
C-501
Lyric Electronics
CNC
Milling Machine
C-501
First Edition
All rights reserved
The material in this book may not be copied, duplicated, printed,
translated, re-edited or broadcast without prior agreement in writing.
Contents
II.......................................................................................C-501 CNC Milling Machine
II..........................................................................................................................Features
II.......................................................................................................Safety instructions:
II...........................................................................................Environmental conditions:
1...................................................................................The system's description
1.1
3........................................................................................G&M-Code language
1.2
6........................................................................Installing the S-MILL software
1.3
7........................................................................................Operating the system
1.4
9.............................................................................................................Monitor
1.5
12.................................................................................Experiment 1.1 Slot Processing
19...............................................................................................Experiment 1.2 Arches
25............................................................................Experiment 1.3 Profile Processing
32............................................................................Experiment 1.4 Pocket Processing
38...............................................................................Experiment 1.5 Drill Processing
43...........................................................................Experiment 1.6 Project Processing
44..................................................................................................FANUC screen
1.6
SES
II
Features
SES
III
Safety instructions:
Read and understand these entire instructions before proceeding.
Keep these instructions.
The operation of the system should only be attempted by experienced
and knowledgeable persons.
Use milling step resolution not over 1mm and adapt the feeding speed
to the processed material.
Always run a milling program on simulation mode before running it on
machine mode.
Never run a milling program without supervising the system.
Use the emergency stop button for emergency stop.
Disconnect the system from electrical supply before servicing for any
reason.
Servicing should be performed by QUALIFIED PERSONNEL ONLY!
Do not operate the system with damage cord, wires or electrical parts.
Operate the system only with the enclosed power supply or with
suitable power supply supplied by the system manufacturer.
Clean only with dry cloth.
Do not install near any heat sources such as radiators, heat registers or
other apparatus that produce heat.
Unplug the power supply and the computer during lighting storms or
when unused for ling periods of time.
Environmental conditions:
Do not expose the system to any kind of liquid.
Operating temperature: 0C to +45C
Humidity: up to 95% at 35C
Power requirements:
Rated voltage: 24 V
Input current: 6 A
SES
1.1
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1.2
G&M-Code language
The software ignores lines that do not start with the letter G or M.
For example, G1 X10 Y30 Z-15 F125 meaning:
Move in straight line to point X,Y,Z = 10,30,15 from the home
position at feed of 125 millimeters per minute.
The movement is done in 3D dimensions.
2)
3)
R
I,J
I,J
0o
Examples:
G10 R10 C30 I25 J20
G10 C180
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4)
R
Co
I,J
0o
Examples:
G11 R10 C30 I25 J20 F200
G11 C180
5)
6)
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7)
G81 Zzz:
Z axis movement for drilling.
8)
G4:
"Wait" instruction, usually applied for stopping in order to replace the
milling cutter or the processed material.
A message appears on the screen and the PC waits for clicking OK to
continue.
2)
1.3
To run the S-MILL software you have to double click over this icon.
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1.4
The C-501 power supply is an external power supply that supplies low DC
voltage to the C-501 controller. The C-501 controller communicates with
the PC in serial communication (RS232 or USB).
The power supply is connected to the C-501 by two wires.
The C-501 controller communication socket and RST pushbutton are
located on the right panel.
Step 1:
Connect the red wire to the + (red) terminal of the power supply.
Connect the red and black wire to the (black) terminal of the
power supply.
Step 2:
Step 3:
Step 4:
Step 5:
Step 6:
Step 7:
Click with the mouse over the S-MILL icon on your desktop.
An introductory screen will appear on the screen.
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Step 8:
Step 9:
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1.5
Monitor
Step 1:
The C-501 has 3 limit switches that indicate the absolute home
position for each axis.
The monitor has three home check points (Home X, Home Y, and
Home Z). Clicking over the check points add/delete the mark
in the check point.
Clicking over the GO TO MACHINE HOME button returns the
marked axis to home position.
Mark all the three axes and click on the GO TO MACHINE
HOME button.
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Important Note:
After turning on the C-501 or pressing 'RST', the monitor
command 'GO TO MACHINE HOME' for all dimensions
(X,Y,Z) must be instructed in order to synchronized the
interface with the system location.
Step 3:
Step 4:
Step 5:
Step 6:
You can move the material (X-Y movement) and the cutter (Z
movement) by using the UP-DOWN buttons for each axis.
Check that.
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Step 7:
Step 8:
You can define any point as the project home using the button
'Define Project Point'.
Click on the 'Define Project Point' button and the X,Y,Z fields of
the project are set to zero.
Step 9:
Move the system using the arrow keys and X,Y,Z fields will be
updated accordingly.
Step 10: Click over the button 'Go To Project Home' and the system will
return to the defined project home point.
Check that.
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Equipment required:
PC computer
S-MILL software
C-501
3mm milling cutter
80x90x10 mm plastic material
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Discussion:
In milling we have several processing types: Slot, Profile, Pocket and Drill.
In slot processing the milling machine creates a slot according to the width
of the milling cutter.
In this experiment we will mill a slot according to the following drawing on
a 90x80x20 mm material.
z
1
10
20
10
10
2
90
20
20
9
10
6
8
20
10
10
20
10
10
30
80
x
Figure 1-2
The symbol
indicates the project home position. It is also the origin of
the axes. The X,Y,Z absolute values relate to this point.
The circle
at point 1 indicates the milling cutter diameter and the milling
starting point.
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Project home:
The program values are related to the project home.
After installing the matter on the table, we are moving the cutter to the
project home point and determine this as the project home by clicking on a
certain button of the monitor program.
Clearance movement:
Clearance movement is a movement to a point without milling at a certain
level above the material.
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Procedure:
Step 1:
Step 2:
Step 3:
Step 4:
Step 5:
Step 6:
Click with the mouse over the S-MILL icon on your desktop.
An introductory screen will appear on the screen.
Step 7:
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Step 8:
M4
G0
G0
G1
G1
G1
G1
G1
G1
G1
G1
G1
G1
G0
G0
M5
S2000
Z3
X20 Y50
Z-1 F100
Y60
X30 Y70
X50
X60 Y60
Y30
X50 Y30
X30
X20 Y40
Y50
Z3
X0 Y0
Step 9:
Step 10: Select the function FILE and the SAVE AS sub-function.
A dialog window is opened requesting the file name.
Step 11: Type the name SLOT1 and click OK.
The program is saved under the name SLOT1.TAP.
Step 12: Select the OPTIONS function again.
Select the SIMULATION sub-function.
In simulation mode, the software simulates the
machine behavior on the screen, without processing the
material.
This option enables us to check our program before milling the
material.
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Step 13: Select the function RUN and the RUN sub-function.
A graph window appears.
The program is executed step by step graphically on the window.
Observe the drawing.
The colors of the lines describe the Z-dimension of the lines.
Step 14: If the graph is not correct according to the program, correct the
program and run it again.
Step 15: Locate the material (90x80x20 mm plastic material) on the table
of the C-501 and tighten it with the handy screws.
Check that the material lies horizontally on the table.
Step 16: Select the OPTIONS function and the MACHINE sub-function
in order to operate the system.
Step 17: Select the function MONITOR and the sub-function CNC
MONITOR.
The CNC monitor appears.
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Make sure that all the check boxes of 'Home X', 'Home Y' and
'Home Z' are checked, and press the "GO TO MACHINE
HOME" button.
The machine should move to the absolute home position.
Step 18: Move the cutter center to the relative project home with the
STEPS (mm) and the MOVE buttons.
Step 19: Turn ON the milling motor by clicking over the "Start Spindle
Motor" button.
Step 20: Lower the cutter slowly until the cutter almost touches the
material surface.
Step 21: Press the "DEFINE PROJECT HOME" button.
Step 22: Select the RUN function and the RUN sub-function.
The system should mill the material according to the program.
Warning:
Dont cut more than 1mm each time.
Cutting more than 1mm can brake the tool or jam the
machine.
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Equipment required:
PC computer
S-MILL software
C-501
3mm milling cutter
90x80x20 mm plastic material
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Discussion:
An arch is part of a circle. To define an arch we define the center of its
circle and the starting point on the circle's perimeter (see the description of
G10 and G11 instructions).
In this experiment we will mill an arch according to the following drawing
on a 90x80x20 mm material.
z
1
10
4
5
90
40
10
10
20
10
40
10
80
Figure 1-3
Because of the drawing complete symmetry, we do not need to indicate all
the measurements.
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Procedure:
Step 1:
Step 2:
Step 3:
Step 4:
Step 5:
Step 6:
Click with the mouse over the S-MILL icon on your desktop.
Step 7:
Step 8:
M4
G0
G0
G1
G02
G02
G02
G02
G1
G0
G0
M5
S2000
Z3
X10 Y50
Z-1 F100
I20 J70 R10 C180 E90
I60 J70 R10 C90 E0
I60 J30 R10 C0 E270
I20 J30 R10 C270 E180
Y50
Z3
X0 Y0
Step 9:
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Step 10: Select the function FILE and the SAVE AS sub-function.
A dialog window is opened requesting the file name.
Step 11: Type the name ARC1 and click OK.
The program is saved under the name ARC1.TAP.
Step 12: Select the OPTIONS function again.
Select the SIMULATION sub-function.
In simulation mode, the software simulates the
machine behavior on the screen, without processing the
material.
This option enables us to check our program before milling the
material.
Step 13: Select the function RUN and the RUN sub-function.
A graph window appears.
The program is executed step by step graphically on the window.
Observe the drawing.
The colors of the lines describe the Z-dimension of the lines.
Step 14: If the graph is not correct according to the program, correct the
program and run it again.
Step 15: Locate the material (50x50x10 mm plastic material) on the table
of the C-501 and tighten it with the handy screws.
Check that the material lies horizontally on the table.
Step 16: Select the function MONITOR and the sub-function SES
MONITOR.
The CNC monitor appears.
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Make sure that all the check boxes of 'Home X', 'Home Y' and
'Home Z' are checked, and press the "GO TO MACHINE
HOME" button.
The machine should move to the absolute home position.
Step 16: Select the OPTIONS function and the MACHINE sub-function
in order to operate the system.
Step 17: Select the function MONITOR and the sub-function CNC
MONITOR.
The CNC monitor appears.
Make sure that all the check boxes of 'Home X', 'Home Y' and
'Home Z' are checked, and press the "GO TO MACHINE
HOME" button.
The machine should move to the absolute home position.
Step 18: Move the cutter center to the relative project home with the
STEPS (mm) and the MOVE buttons.
Step 19: Turn ON the milling motor by clicking over the "Start Spindle
Motor" button.
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Step 20: Lower the cutter slowly until the cutter almost touches the
material surface.
Step 21: Press the "DEFINE PROJECT HOME" button.
Step 22: Select the RUN function and the RUN sub-function.
The system should mill the material according to the program.
Warning:
Dont cut more than 1mm each time.
Cutting more than 1mm can brake the tool or jam the
machine.
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Equipment required:
PC computer
S-MILL software
C-501
3 mm milling cutter
90x80x20 mm plastic material
Discussion:
In profile type processing, the cutter is attached to the drawing geometry. It
means that it mills around the marked area.
After the processing, the marked area will stick out over the profile cutting.
In profile processing the drawing lines are not the milling lines. We have to
take care of the cutter width. The cutter should go outside the marked area.
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90
80
5
5
70
80
Figure 1-4
Our cutter width is 3mm. Because the cutter width is smaller then the space
between the profile lines and the edges of the material, the processing is
done in two cycles.
The home position will be also the starting point.
We can't process the material in any depth at one cycle. If we want to go
deep, we do it in several cycles. The number of cycles depends on the
hardness of the material.
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Procedure:
Step 1:
Step 2:
Step 3:
Step 4:
Step 5:
Step 6:
Click with the mouse over the S-MILL icon on your desktop.
Step 7:
Step 8:
Step 9:
M4 S2000
G1 Z-1 F100
G1 X1
G1 Y89
G1 X89
G1 Y1
G1 X3.5
G1 Y76.5
G1 X76.5
G1 Y3.5
G1 X3.5
G0 Z3
G0 X0 Y0
M5
Compare the program with the drawing. Check each instruction
and mark the cutter path on the drawing.
Step 10: Select the function FILE and the SAVE AS sub-function.
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Step 17: Select the function MONITOR and the sub-function CNC
MONITOR.
The CNC monitor appears.
Make sure that all the check boxes of 'Home X', 'Home Y' and
'Home Z' are checked, and press the "GO TO MACHINE
HOME" button.
The machine should move to the absolute home position.
Step 18: Move the cutter center to the relative project home with the
STEPS (mm) and the MOVE buttons.
Step 19: Turn ON the milling motor by clicking over the "Start Spindle
Motor" button.
Step 20: Lower the cutter slowly until the cutter almost touches the
material surface.
Step 21: Press the "DEFINE PROJECT HOME" button.
Step 22: Select the RUN function and the RUN sub-function.
The system should mill the material according to the program.
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Challenge Exercise
Step 23: Change the program to create round corners (with 5 mm radius)
of the profile processing.
Check the program on simulation.
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Equipment required:
PC computer
S-MILL software
C-501
3 mm milling cutter
90x80x20 mm plastic material
Discussion:
In pocket processing the processing is done in a closed geometry area.
There are several types of movements in order to cover the area.
For smooth and better finish of the area, the movements must partially
overlap.
In CLEAR type we get out the pocket area by half diameter of the milling
cutter. The milling is done up and down in spaces of half diameter.
Figure 1-5
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In HATCH+FINISH type the milling cutter also goes up and down in half
diameter spaces, but the finish cutting is done inside the pocket contour
lines and is attached to them.
Figure 1-6
In CONTOUR type the milling cutter moves along the contour lines in
decreasing loops. The CONTOUR type is usually the most efficient one.
Figure 1-7
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90
20
40
30
20
80
Figure 1-8
The processing type will be the contour type.
Be aware that the pocket contour lines are always round at the corners
according to the milling cutter diameter.
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Procedure:
Step 1:
Step 2:
Step 3:
Step 4:
Step 5:
Step 6:
Click with the mouse over the S-MILL icon on your desktop.
Step 7:
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Step 8:
Step 9:
S2000
Z3
X40 Y49
Z-1
F100
X39
Y51
X41
Y49
X40
Y47
X37
Y53
X43
Y47
X40
Y45
X35
Y55
X45
Y45
X40
Y43
X33
Y57
X47
Y43
X40
Y41.5
X31.5
Y58.5
X48.5
Y41.5
X40
Z3
X0 Y0
Step 10: Select the function FILE and the SAVE AS sub-function.
A dialog window opens requesting the file name.
Step 11: Type the name POCKET1 and click OK.
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Step 17: Select the function MONITOR and the sub-function CNC
MONITOR.
The CNC monitor appears.
Make sure that all the check boxes of 'Home X', 'Home Y' and
'Home Z' are checked, and press the "GO TO MACHINE
HOME" button.
39
Equipment required:
PC computer
S-MILL software
C-501
3mm milling cutter
90x80x20 mm plastic material
Discussion:
Drill is a process done on single point geometry.
For drilling we replace the milling cutter with a drill, which goes on Z
dimension only (up and down).
We select a drill with a diameter according to the required diameter hole.
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40
90
40
30
20
40
80
Figure 1-9
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Procedure:
Step 1:
Step 2:
Step 3:
Step 4:
Step 5:
Step 6:
Click with the mouse over the S-MILL icon on your desktop.
Step 7:
Step 8:
S2000
Z3
X20 Y30
Z-3 F100
Z3
Y70
Z-3
Z3
X60
Z-3
Z3
Y30
Z-3
Z3
X0 Y0
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Step 9:
Step 10: Select the function FILE and the SAVE AS sub-function.
A dialog window opens requesting the file name.
Step 11: Type the name DRILL1 and click OK.
The program is saved under the name DRILL1.TAP.
Step 12: Select the OPTIONS function and the SIMULATION subfunction in order to check the program by simulation.
Step 13: Select the function RUN and the RUN sub-function.
A graph window appears.
The program is executed step by step graphically on the window.
Observe the drawing.
Step 14: If the graph is not correct according to the program, correct the
program and run it again.
Step 15: Locate the material (90x80x20 mm plastic material) on the table
of the C-501 and tighten it with the handy screws.
Check that the material lies horizontally on the table.
Step 16: Select the OPTIONS function and the MACHINE sub-function
in order to operate the system.
Step 17: Select the function MONITOR and the sub-function CNC
MONITOR.
The CNC monitor appears.
Make sure that all the check boxes of 'Home X', 'Home Y' and
'Home Z' are checked, and press the "GO TO MACHINE
HOME" button.
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Equipment required:
PC computer
S-MILL software
C-501
3mm milling cutter
90x80x20 mm plastic material
Procedure:
Step 1:
Step 2:
Step 3:
Step 4:
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1.6
FANUC screen
Step 1:
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46
Monitor Functions
Step 2:
The C-501 has 3 limit switches that indicate the absolute home
position for each axis.
Clicking over the GO TO MACHINE HOME button returns the
marked axis to home position.
Check that.
Important Note:
After turning on the C-501 or pressing 'RST', the monitor
command 'GO TO MACHINE HOME' for all dimensions
(X,Y,Z) must be instructed in order to synchronized the
interface with the system location.
Step 3:
Step 4:
Step 5:
Step 6:
You can move the material (X-Y movement) and the cutter (Z
movement) by using the arrow buttons for each axis.
The monitor displays the current position of the machine in the
X,Y,Z fields on the blue screen.
Check that.
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Step 7:
Step 8:
Step 9:
You can define any point as the project home using the button
'Define Project Point'.
Click on the 'Define Project Point' button and the X,Y,Z fields of
the project are set to zero.
Step 10: Move the system using the arrow keys and X,Y,Z fields will be
updated accordingly.
Step 11: Click over the button 'Go To Project Home' and the system will
return to the defined project home point.
Check that.
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Program Functions
Step 1:
The left side of the window is for program writing and editing.
The program is written in the blue screen on the top.
You can click on the keyboard buttons such as letters, digits and
functions (Space, Back space, Enter and Delete). Clicking the
Shift key shifts the function of the buttons from one to the other.
This is a simulation of using a machine keyboard.
On the other hand, you can use the PC keyboard to write and edit
your program.
Click on the left side of the blue screen to move the cursor to
there and type the following program.
M4
G0
G0
G1
G1
G1
G1
G0
G0
M5
S2000
Z3
X5 Y5
Z-1 F100
Y45
X45
Y5
Z3
X0 Y0
Step 2:
Step 3:
Step 4:
Step 5:
Step 6:
49
Step 7:
Move the cutter center to the relative project home with the
arrow buttons.
Step 8:
Step 9:
Lower the cutter slowly until the cutter almost touches the
material surface.
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