Mach2Mill_6.11.pdf

Auser'sguidetoinstallation,

configurationandoperation

Using Mach2Mill

The nurture, care and feeding of the Mach2

controlled CNC Mill

All queries, comments and suggestions welcomed via support@artofcnc.ca

Mach Developers Network (MachDN) is currently hosted at:

http://groups.yahoo.com/group/mach1mach2cnc/files/

Front cover: A vertical mill circa 1914

Back cover (if present): The old, gear, way of co-ordinating motion on mill table and a

rotary axis

For Mach2Mill Release 6.11

Manual Revision 6.11-C 1

Contents

Preface.............................................................................................1-1

Introducing CNC machining systems............................................2-2

2.1

Parts of a machining system...........................................................................................2-2

2.2

How Mach2 fits in...........................................................................................................2-2

An overview of Mach2 Machine Controller software...................3-1

3.1 Installation......................................................................................................................3-1

3.1.1 Downloading....................................................................................................................3-1

3.1.2 Installing...........................................................................................................................3-1

3.1.3 The vital re-boot...............................................................................................................3-1

3.1.4 Convenient desktop icons..................................................................................................3-2

3.1.5 Testing the installation......................................................................................................3-2

3.1.6 OCXTest after a Mach2 crash...........................................................................................3-3

3.1.7 Notes for manual driver installation and un-installation......................................................3-3

3.2 Screens............................................................................................................................3-4

3.2.1 Types of object on screens................................................................................................3-4

3.2.2 Using buttons and shortcuts...............................................................................................3-5

3.2.3 Data entry to DRO............................................................................................................3-5

3.3 Jogging............................................................................................................................3-5

3.4 Manual Data Input (MDI) and teaching.........................................................................3-7

3.4.1 MDI.................................................................................................................................3-7

3.4.2 Teaching...........................................................................................................................3-7

3.5 Wizards – CAM without a dedicated CAM software.....................................................3-8

3.6 Running a G-code program............................................................................................3-9

3.7 Toolpath display............................................................................................................3-11

3.7.1 Viewing the toolpath.......................................................................................................3-11

3.7.2 Panning and Zooming the toolpath display......................................................................3-11

3.8

Other screen features....................................................................................................3-11

Hardware issues and connecting the machine tool.....................4-1

4.1 Safety - emphasised.........................................................................................................4-1

4.2 What Mach2 can control.................................................................................................4-1

4.3 The EStop control...........................................................................................................4-2

4.4 The PC parallel port.......................................................................................................4-3

4.4.1 The parallel port and its history.........................................................................................4-3

4.4.2 Logic signals.....................................................................................................................4-3

4.4.3 Electrical noise and expensive smoke................................................................................4-4

4.5 Axis drive options............................................................................................................4-5

4.5.1 Steppers and Servos..........................................................................................................4-5

4.5.2 Doing Axis drive calculations...........................................................................................4-6

4.5.3 How the Step and Dir signals work....................................................................................4-7

4.6 Limit and Home switches................................................................................................4-8

4.6.1 Strategies..........................................................................................................................4-8

4.6.2 The switches.....................................................................................................................4-8

4.6.3 Where to mount the switches.............................................................................................4-9

4.6.4 How Mach2 uses shared switches....................................................................................4-10

4.6.5 Referencing in action......................................................................................................4-10

CNC Machining with Mach2Mill

Rev 6.11-C 1

Contents

4.6.6 Other Home and Limit options and hints.........................................................................4-11

4.7

Spindle control..............................................................................................................4-11

4.8

Coolant..........................................................................................................................4-13

4.9

Plasma torch height control (THC)..............................................................................4-13

4.10

Knife direction control..................................................................................................4-14

4.11

Digitise probe................................................................................................................4-14

4.12

Linear (glass scale) encoders.........................................................................................4-14

4.13

Spindle index pulse.......................................................................................................4-15

4.14

Charge pump - a pulse monitor....................................................................................4-15

4.15

Other functions.............................................................................................................4-15

Configuring Mach2 for your machine and drives.........................5-1

5.1 A configuration strategy.................................................................................................5-1

5.2 Initial configuration........................................................................................................5-1

5.2.1 Defining addresses of port(s) to use...................................................................................5-2

5.2.2 Defining axes to be used...................................................................................................5-2

5.2.2.1 Controlled axes......................................................................................................5-2

5.2.2.2 Spindle..................................................................................................................5-2

5.2.3 Defining engine frequency................................................................................................5-2

5.3 Defining input and output signals that you will use.......................................................5-3

5.3.1 Output signals to be used...................................................................................................5-3

5.3.2 Input signals to be used.....................................................................................................5-4

5.4 Allocating Inputs and Outputs to ports and pins...........................................................5-5

5.4.1 Defining output pins.........................................................................................................5-5

5.4.2 Defining input pins...........................................................................................................5-5

5.4.2.1 Emulator setup.......................................................................................................5-6

5.4.2.2 Parallel input setup.................................................................................................5-8

5.4.3 Encoder inputs..................................................................................................................5-9

5.4.4 Assign Relay Activation Outputs.......................................................................................5-9

5.4.5 Testing.............................................................................................................................5-9

5.5 Defining the setup units................................................................................................5-10

5.6 Tuning motors...............................................................................................................5-10

5.6.1 Calculating the steps per unit...........................................................................................5-11

5.6.1.1 Calculating mechanical drive................................................................................5-11

5.6.1.2 Calculating motor steps per revolution..................................................................5-12

5.6.1.3 Calculating Mach2 steps per motor revolution......................................................5-12

5.6.1.4 Mach2 steps per unit............................................................................................5-13

5.6.2 Setting the maximum motor speed...................................................................................5-13

5.6.2.1 Practical trials of motor speed...............................................................................5-13

5.6.2.2 Motor maximum speed calculations......................................................................5-14

5.6.3 Deciding on acceleration.................................................................................................5-14

5.6.3.1 Inertia and forces..................................................................................................5-14

5.6.3.2 Testing different acceleration values.....................................................................5-14

5.6.3.3 Why you want to avoid a big servo error...............................................................5-14

5.6.3.4 Choosing an acceleration value.............................................................................5-14

5.6.4 Saving and testing axis....................................................................................................5-15

5.6.5 Repeat configuration of other axes..................................................................................5-16

5.6.6 Spindle motor setup........................................................................................................5-16

5.6.6.1 Motor speed, spindle speed and pulleys................................................................5-16

5.6.6.2 Pulse width modulated spindle controller..............................................................5-17

5.6.6.3 Step and Direction spindle controller....................................................................5-18

5.6.6.4 Testing the spindle drive......................................................................................5-18

5.7 Other configuration......................................................................................................5-19

5.7.1 Configure homing...........................................................................................................5-19

Rev 6.11-C 1

iii

CNC Machining with Mach2Mill

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