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The manual guides the correct procedures for installing and operating the MTAB XLMILL
machine. All the installation process should be carried out out by MTAB approved personnel.
This manual provides installation and maintenance guidelines for the XLMILL that performs
drilling, boring, reaming, pocketing, grooving, threading, parting, roughing, chamfering, tapping
of circular and rectangular work pieces, using CNC programming and operating software.
The XLMILL is specifically designed for Education and Training, and is manufactured
according to industrial standards. The Mill is capable of cutting resistant materials and is totally
enclosed by high visibility guard.
If you have any doubts and/or questions regarding the specifications, features and
operations of the machine, Please contact customer service at MTAB.
COPYRIGHT©
No part of this publication may be reproduced in any form, without the prior permission of
MTAB. MTAB holds the right to modify or change an y part of the document without any notification.
The authorized user of this manual shall acquire no rights in resp ect of trademarks or other intellectual
property rights referred to herein which are and shall remain the property of the owner thereof
E-mail: mtabd3.vsnl.net.in
Web site:www.mtabindia.com
Safety notices
This Manual contains notices that are intended to ensure your personal safety and to avoid
any material damage. The notices are highlighted by a warning triangle and, depending on the
degree of hazard, represented as shown below:
Caution/Precaution
Indicates that minor personal injury or material damage may result, if the appropriate precautions
are not taken
Note
Is used to draw your special attention to important information on the product, handling of the
product or the corresponding part of the documentation.
Table of contents
1. Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Introduction of the Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Description of XLMILL Machine . . . . . . . . . . . . . . . . . . . . . . 5
Operating Procedure for non ATC Machines: . . . . . . . . . . . . . . . . . . . . 7
Back view of XLMILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4. Structure and specifications: . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5. Machine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Unpacking of XLMILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..16
UpLifting of XLMILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Requirements for Machine Connection . . . . . . . . . . . . . . . . . . . . . . . . 18
6. CNC TRAIN Installation procedure . . . . . . . . . . . . . . . . . . . . .19
Installation of the security Dongle on the parallel port of the CPU . . .22
7. Machine Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8. Software Operating Procedure . . . . . . . . . . . . . . . . . . . . . . . . 29
Getting started with CNC Train. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Selection of Machine Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Main Menu Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Procedure for machining the sample program . . . . . . . . . . . . . . . . . . 48
9. Exercises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
M codes . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . 59
G codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Sample Programs . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 71
10. Maintenance Procedure: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
11. Trouble Shooting: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
CNC Machine XLMILL control side trouble Shooting: . . . . . . . . . . .84
12. Control Panel Layout . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . 86
13. ElectricalDrawing . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . 87
14. Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Safety Precautions XLMILL User Manual
1. Safety Precautions
These safety instructions are intended to prevent hazardous situations and/or equipment damage.
These instructions indicate the level of potential hazard by labels of Cautions, Warning orDanger”.
The machine has safety devices fitted to pr otect the machine and the operator from unexpected
accidents.
i. Tidiness
̀ Do not place objects that interface with the guard or during the operation of the machine,
̀ Do not place objects ON or around the machine.
iii. Lubrication
Refer maintenance section for safety during lubrication.
.
Check the status of slideway lubrication daily
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Operating Environment
Do not use in environment where the products are directly exposed to corrosive gases,
Chemicals, salt water etc.
Do not expose the products to direct sunlight for an extended period of time.
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Introduction and Description XLMILL User Manual
Figure 2
The manual provides the installation and maintenance guidelines for the XLMILL that performs
drilling, reaming, pocketing, grooving, parting, roughing and chamfering of circular and rectangular work
pieces, using CNC programming and operating software. The Mill is spec ifically designed for Education
and Training, and is manufactured in accordance to the industrial standards.
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Introduction and Description XLMILL User Manual
Optional Equipments
Automatic Tool Changer(ATC)
Hydro- Pneumatic Vice
Automatic Door
Work Bench software.
Software supplied:
CNCTrain software CD
Tools Kit:
Collet chuck ISO 30/A45 RD 25 with Pull Stud
Collet chuck ISO 30/A45 RD 16 with Pull Stud
RD 25 Collets Dia 5,6,8,10,12,16 mm
RD 25 Collets Dia 3,4,5 mm
2 Lipped Cardibe slot Mill for facing shank dia 16mm
Clamping Kit
Set of HSS Mill Dia 5, 6, 6, 6, 8 mm
Set of HSS Mill Dia 10, 12, 16 mm
HSS Slot Drills Dia 5, 6, 6, 6, 8 mm
HSS Slot Drills Dia 10, 12, 16 mm
Maintanence Tools
Allen Key
Screwdriver set
Double Ended Spanner
C Spanner
Spanner MorBox Type -E25
Spanner E 16
Oilcan with oil
Oil Gun
Additional offline programming software
PC workstation
Fuses -1set /8Nos of fuse Pack
FMS equipment and system integration.
Machine Cover
Datum Plate and Billet Clamp
Lubrication Pump
PU 8 Hose
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Description of XLMILL Machine XLMILL User Manual
Figure 3.1
The XLMILL is totally enclosed by a high visibility guard. The XLMILL Machine inspection and func-
tions are carried out in the following schedule.
i Hydro Pneumatic Pressure intensifier with Single Acting Cylinder
ii ATC Automatic Tool Changer
iii Hydro Pneumatic Vice
Due to the Hydro pneumatic pressure the jaw in the vice will move in -X, +X axis to either clamp or
unclamp the billet.
Hydro - Pneumatic Intensifier
Figure 3.2
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Description of XLMILL Machine XLMILL User Manual
Figure 3..3
In Hydro Pneumatic Vice, the cylinder is connected to the Pneumatic Intens ifier with a
tube.
Movable jaw in the vice helps in holding the billet.
Fixed jaw is immovable in this device.
Figure 3.4
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Description of XL MILL Machine XLMILL User Manual
View of ToolHolder
Figure 3.5
Figure 3.6
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To fix a tool, the lever with key has to be fixed in the socket on the spindle head.
Figure 3.7
Insert the Key in the socket on the spindle head with the help of the lever.
Figure 3.8
i. Move the lever towards the backside of the machine to open the tool holder.
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Description of XLMILL Machine XLMILL User Manual
Figure 3.9
After fixing the tool move the lever in the other direction to lock the tool.
Figure 3.10
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Description of XLMill Machine XLMILL User Manual
Figure 3.11
Figure 3.12
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DRAIN
Maximum pressure for air regulator is 9.9 Kg F / cm (150 lbs sq”).The Op erating pressure 100lbs
sq."(6.9 Bar). Check the main supply pressure before adjusting pressu re at the regulator. Air filters on the
both side of the machine should be changed annually.
To adjust the pressure pull up the rotary control, un lock it from its current position. Turn the control to
clockwise to increase pressure, and anti-clockwise to decrease the pressure. Push the rotary control down
to relock it in its new position. Regu larly drain the water collected in th e filter bottle. The interval at which
this operation is required will depend on the type and condition of the air compressor being used.
The air Lubricator Oil - (Suitable)
Turn the front small adjusting screw clockwise to increase the oil flow, or anti-clockwise to decrease
the oil flow. Oil can be added to the resovior bottle by removing the black cap.
Figure 3.13
Notes :
For Smooth running of the system, it is essential that the power supply is constant and stable
Emergency Stop:
Emergency Stop is used to avoid the eradication du ring the processment of the machine. The user can
use this emergency stop button only during the emergency requirement.
Push the emergency stop switch to stop the machin e and to release the emergency stop, turn the red
knob on the switch in clockwise direction.
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Structure and specification XLMILL User Manual
Figure 4.1
Figure 4.2
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Structure and Specifications XLMILL User Manual
Dimension of XLMILL
Figure 4.3
Siting of XLMILL
The XLMILL should be sited on a bench of robust construction to take the weight of the
mill.
Note : Ensure that sufficient room is allowed while sitting the mill, so as to enable smooth operation,
programming, and effective maintenence of the mill
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Capacity Diagram
Figure 4.4
Figure 4.5
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Table 1: Specifications:
ATC 6 Stations
Repeatability 0.01 mm
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Machine Installation XLMILL User Manual
5. Machine Installation
Unpacking of XLMILL
Machine Packing consist of three packs,
UpLifting of XLMILL
Use crowbars to lift the machine.
Remove the outer wooden packings using claw hammer.
XLMILL is lifted using the crowbars, fixed under the clamps provided at the side of the cabinet. Ensure
that the machine is secure and bala nced while lifting. Always use correct lifting precautions in accordance
with the Health and Safety Regulations in your establishment .
Figure 5.1
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Donts
Don’t operate the machine before cleaning.
Don’t use compressed air for cleaning (Like Air Gun).
Note : Ensure that sufficient room is allowed while sitting the mill, so as to enable smooth
operation, programming, and effective maintenence of the mill
Electrical Connection
Figure 5.2
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Machine Installation XLMILL User Manual
The electrical connection power supply is fed to the electrical control box, and fit in the back of the
machine cabinet , which in turn is connected to the milling machine.
Note:
Do not connect the cables between any electrical hardware with the main power switched ON
Since this could damage the hardware.
Figure 5.3
Description of Connections
Connect the power cable from the Control box to rear portion of the XLMILL machine as
shown in the above diagram.
Connect the USB cable from the Control box to the Computer.
Connect the Control box mains supply (220/240v 1 phase) to power supply point on Stabilizer
and connect the Computer cable to the Stabilizer.
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CNC TRAIN Installation Procedure XLMILL User Manual
Figure 6.1
Figure 6.2
Figure 6.3
This process will start installing the CNC Train on your computer.
Click Next to continue the further setup program.
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CNC TRAIN Installation Procedure XLMILL User Manual
Click browse to choose the destination folder and then click next to continue.
Figure 6.5
Next is selecting the program manager group, select it as CNC SIMULATION as shown below
Figure 6.6
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CNC TRAIN Installation Procedure XLMILL User Manual
Figure 6.7
Figure 6.8
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CNC TRAIN Installation Procedure XLMILL User Manual
Figure 6.9
Figure 6.10
Installation of the security Dongle on the parallel port of the CPU
The following is the procedure to install or activate the security dongle.
i. Fix the security key in the parallel port of the cpu.
Figure 6.11
Figure 6.12
Figure 6.13
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CNC TRAIN Installation Procedure XLMILL User Manual
Figure 6.14
Figure 6.15
Figure 6.16
As soon as the Dongle’s driver is installed you will recieve the following messsage. Click OK.
Figure 6.17
Now the software is ready for the simulation as well as operation of the machine
Opening procedure:
As the installation is completed we can see the CNC TRAIN icon on the desktop and also in the programs
The software can also be opened by the following path as given below.
(Or) to openup in shortcut method Press the CNC TRAIN icon in the desktop.
.
Figure 6.18
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CNC TRAIN Installation Procedure XLMILL User Manual
7. Machine Link
Install the Work Bench software by following the steps given below.
鐀 ̀Double Click the setup installer to launch the installshield software in to the system.
Figure: 7.1
Figure: 7.2
Windows installer
Figure:7.3
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CNC TRAIN Installation Procedure XLMILL User Manual
Figure: 7.4
Click on the accept term in the license agreement, then click on next button.
Figure: 7.5
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CNC TRAIN Installation Procedure XLMILL User Manual
Figure: 7.6
Click Next to install to the Selected folder, or click change to install in a different folder.
Figure: 7.7
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CNC TRAIN Installation Procedure XLMILL User Manual
Click on install button to install the settings, click on cancel to exit the wizard.
Figure:7.8
Now the InstallShield Wizard installs Mint Machine Center and Mint Workbench (5600).
Figure: 7.9
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CNC TRAIN Installation Procedure XLMILL User Manual
Figure: 7 .10
Figure: 7.11
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Software Operating Procedure XLMILL User Manual
Figure 8.1
Click Start > Menu Program > cnctutor > CNC simulation > CNC Train
Figure 8.2
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Software Operating Procedure XLMILL User Manual
CNC Train opens the “Fanuc Mill OM control” In that Enter the password as MASTER in the Pass -
word Box and click ok..
Figure 8.3
Password
Note :
Password is not Case-sensitive.
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Click Here
Figure 8. 4
Click Fanuc O Milling from Control Type Menu to select the machining type. This selection is to run
It Play a vital role in the XL milling machine. It is used to type the Program in the GE Fanuc OM.
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Figure 8. 5
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Figure 8.6
Change the Parameters in the Machine settings, Billet settings, Tool Offsets and Machine control as given,
below pages.
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File Menu:
Figure 8.7
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The main menu lists the set of sub-menus to perform several actions with programs.
Store Memory Use to store the current in the active CNC control memory.
Edit File Used to add the text file in the CNC Editor and amended
Save File Use to save current file appears in the Editor Screen.
Printer Setup Shows the print setup in the Progamming Screen to print th current
file.
Printer It is use to print the file
Figure 8.7.1
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Software Operating Procedure XLMILL User Manual
Click File Menu and click the load Cnc program from the screen Editor.
Click File Menu < Save File
Figure 8..7.2
Edit:
Figure 8.8
The work procedure of Edit Menus is given below.
Table 2: Edit
Font Contain several types of fonts use change the font type in the screen.
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Options
Options Menus explaination is given below,
Figure 8.9
Figure 8.9.1
"Full Screen: It Shows the Full Screen of the Editor Screen
"Set Colors : Set Colors sub menu is used to set the colors on the screen (or) Use to change
color.
Figure 8.10
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Software Operating Procedure XLMILL User Manual
Machine Settings
Select the Job/Tooling from the main menu to set machine setting.The Following display
will appear on the screen.The machine parameter setting should be done USING the
displayed screen
Machine Setting Dialogue Box
Parameter settings
Minimum Traverse
Set the minimum traverse for all the axes. The value must be less than the min -
imum traverse value.
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"Home Positions
Set the Home Positions for value for all the axes. These are the machine posi -
tions when the axes have mo ve to their datum switches
"Spindle
Sets the machine spindle to manual or automatic.
"Home Switches
Tick this box if your machine has da tum switches and you want to axes to
Home to the datum switches
"Homing Speed
Machine type sets the Homing speed for the current.
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Software Operating Procedure XLMILL User Manual
Billet Settings
Figure 8.12
"X,Y.Z Shift
Work shift value are the distances from the positionto the billet
datum position. These values are automatically inserted when you
datum th tool
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"Offsets
Displays the current units of measurement. Switching units can only done
by the site license screen when you first run the software.
Auto Load Work Shift Offsets : Each CNC program stores its own work shifts offsets. If you
want to load these offsets when loadings a CNC programs ticks this option box. By de-
selecting this option you can load CNC programs
"Save Workshift Offsets : Save the current offsetin the current machine type settings file.
Selecting a new machine type loads the work shift for that machine.
" Load Work shift offsets : Loads the current work shift offsets for the active Machine
Type.
"Important : Use Tool 1 when settings the datum position. If you have Auto Tool offsets
ticked you do not have to datum the tools.
Switches between Imperial nad metric. Metric or Imperial values are auto -
matically loaded when selecting this option.
"Billet Length: Set the billet length for a new part program
"Billet Width :Set the billet Width for a new part program:
"Billet Depth : Set the billet Depth for a new part program
"Billet X : (Simulation purpose only) : If the Datum position for
the X axis is not bottom left hand corner of the billet than
you can shift the datum position by typing in a value.
" Billet Y : (Simulation purpose only) If the Datum position for the X axis is not bottom
left hand corner of the billet than you can shift the datum position by typing in a value.
"Billet Z : (Simulation purpose only) : If the datum position for the Z axes is not the top
of the billet then you can shift the datum position by typing the value.
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Tool OffSets
Figure 8.13
Up to 99 tools can be stored in the tool offsets page with all the relevant information for each tool.A
library of tools for a particular machine type or for a part program can be selected and saved to disk.
"TOOLTYPE : This value is the type of tool being used, for example: End mill, Slot Drill
etc. A library of tool types is stored in the Select Tooling page.
"TOOLRAD : The radius of the tool for compensation is stored in this column. This value
depends on the programmer and the G41/G42 tool compensation that he is using.
"ACTUAL DIAM : This value is the actual value of the cutter diameter and will be used
in the simulation to display the tool.
Z LENGTH
This value is the z length offset.
"Option 1 : Type in the Z length offset in the relevant column. This method is suitable for
pre- set tooling.
"Option 2 : Move the tool to the top of the job in Jog Mode and double click in the rele-
vant Z length offset column to automatically transfer the offset from the positional data.
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Software Operating Procedure XLMILL User Manual
Note:
If AutoToolOffsets is selected then Z length offsets will not be used.
TOOL LENGTH
This value is the actual tool length.
" Option 1 : Type in the tool length by measuring the actual tool and placing the value in
the relevant column.
" Option 2 : Move the cursor to the cutter on the screen, press the left mouse button and
drag the tool up or down to the required length. The value will be automatically inserted
into the relevant Tool Length column.
CHUCK LENGTH
This value is the actual chuck length.
" Option 2 : Move the cursor to the chuck on the screen, press the
mouse on left button and drag the chuck up or down to the required
length. The value will be automatically inserted into the relevant Chuck Length column.
CHUCK TYPE
This value is the name of the chuck that you want to use. A library of chuck types can be created on the
Select Tooling page.
CHUCK WIDTH
Chuck width can be used in the same way as chuck length but specifies the chuck diameter.
With the machine control software this option is not available. You must always set your tool offsets
-
when controlling a CNC machine tool. For simulation purposes tick Auto Tool Offsets if you want the off
sets to be calculated automatically. Untick this option to force the student to set tool offsets.
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Tool Selection:
Figure 8.14
View a Tool
The system comes with a selection of tools. To select a tool point to the tool name in the list box and
double click with the left button of the mouse. The relevant bitmaps will be displayed in the boxes.
Add a Tool: You can define and add your own tools by defining
the bitmaps and the tool geometry.
Delete a Tool : Highlight the tool name in the listbox and press
the Delete key on the qwerty keyboard. The tool name will be deleted
from the list.
Chuck List : Chuck bitmaps can be added and removed in the same
manner as the tool bitmaps.
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Figure 8.15
Machine Control dilogue box is use to set or arrange the machine control settings to their suitable
work. After completing the setting Click Ok.
Figure 8.16
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The following box appear and change the set up value as shown in the parameter box(This setting is
only for the desktop Keyboard).
Figure 8.17
Control type
Figure 8.18
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MDI Panel :
MDI Panel is use on the screen to generate CNC programs by clicking the machine on the relavent but-
ton wtih the On - screen control.
Figure 8.19
Figure 8. 20
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Software Operating Procedure XLMILL User Manual
" Machine Link option :It is only available with machine software switches they link
between the computer and the CNC machine tool off/on.
" After connecting to the CNCmachine tool for the first time you can untick the machine
link and simulate to the CNC programs.This will allow you to test the CNC program before cut-
ting the part on the machine. Next step, NextMoveST, NextMoveESB, Show Mint 328, Set Dnc/
Tutor omms Link, Set Machine Comms Link,
" Receive File, Send File : Use to Send and Recieve the particular through these files.
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M30
End
Enterlength
EnterWidth
Enter Depth
Figure 8.21
"Select Billet from the Job/Tooling menu and arrange the settings.
"Click “Ok” to Save workshift Offsets
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iii. Simulation:
Simulation of Milling the Billet. When starting the machine the machine link should be deactivated
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Step 1 : Billet 100X100 is fixed in the table using clamp and jaws. Touch the work piece at
the lefthand side using dia 6mm cutter
Zero Point
Step 2 : Click X offset in the CNC Display screen to move the cutter in X axis Direction.
Press + button in the CNC control. Press Datum to move
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Press X
Click Here
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Cutter in center
53mm
Step 5 : Move the cutter about 53mm. Place the cutter in center.
Press
Figure 8.22
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Change
X&Y
Shift
Figure 8.23
Taking Y Offsets
Touch
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Step 2 : Click the Datum and press Y from the CNC Display screen
Figure 8.24
Step 3 : Move the cutter up in Z directionStep 4 : Move the cutter 53mm to place the cutter
in center.
Z direction
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Step 5 : Press Datum and Click Y from the CNC Display screen
Figure 8.25
Step 6 : Click Billet setting from the Job/Tooling menu and verify the settings.
Change
X Axis
Shift
Figure 8.26
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Step -2 : Select Job/Tooling Menu to open the Tool Offsets. And double Click on the Z
Offsets column.And click Ok to continue.
0.
Figure 8.27
Step-3 : Click Auto in the simulaion screen. And press Cycle Start to finish up the work to
give the final output.
Figure 8.28
Step- 4 :Store the current CNC program in the active control memory todisk with its set-
tings.
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Exersices XLMILL User Manual
9. Exercises
Introduction.
Each part program contains a number of different codes, the most important being the
collection of G and M codes. Essentially, these form the basic language used to describe
how a component will be manufactured, the order in which to carry out machining tasks,
when to change tools, how far to cut into the material etc.....
The helpfile is divided into three main sections, each with their own list of topics:
1) Basic Programming - This section builds progressively, using plain, easy to follow
text, to cover the general layout and commands of a part program. At the end of this
stage, the operator should be confident enough to tackle basic part programming.
2) G Codes - This section should be used as a reference guide, once the operator is
confident with the basics of programming. It contains detailed information, specific to
certain Preparatory Fuction commands used by the system.
3) M Codes - This section should be used as a reference guide, once the operator is
confident with the basics of programming. It contains detailed information, specific to
certain Miscellaneous Fuction commands used by the system.
List of M Codes
MØØ (Program Stop).
MØ1 (Optional Stop).
MØ2 (End of Program).
MØ3 (Spindle Forward).
MØ4 (Spindle Reverse).
MØ5 (Spindle Stop).
MØ6 (Automatic Tool Change).
MØ8 (Coolant On).
MØ9 (Coolant Off).
M1Ø (Chuck Open).
M11 (Chuck Close).
M13 (Spindle Forward and Coolant On).
M14 (Spindle Reverse and Coolant On).
M25 (Tailstock Quill Extend).
M26 (Tailstock Quill Retract).
M3Ø (Program Stop and Reset).
M4Ø (Parts Catcher Extend).
M41 (Parts Catcher Retract).
M62 / M63 / M64 / M65 / M66 / M76 / M77 (Auxiliary Output Functions).
M98 (Sub Program Call).
M99 (Sub Program End and Return).
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M CODES:
M Codes (Miscellaneous Functions) - Introduction.
Miscellaneous functions, called M codes, are used by the CNC to command on/off
signals to the machine functions. ie, MØ3 - spindle forward (CW), MØ5 - spindle stop,
etc..... The functions allocated to lower M code numbers are constant in most CNC
controls, although the higher M code number functions can vary from one make of
controller to the next.
M08 Coolant On
M08 turns the coolant on.
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Example : At the time of tool changing operation the screen will display the current station number
which is engaged for particular operation.
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COMMANDS DESCRIPTION
These commands are available in the machine side
The Robot inputs can be switched on by sendi ng the output signal from machine side to Robot
side as a input signal.
NOTE: M76/67/66/77
These M Codes are available in the machine side. The machine side inputs can be switched on by
transferring the output signal from Robot side to machine aide as a input signal.
The machine inputs can be switched on by transferring the high signal which comes from the Robot
side. The machine inputs can be switched off by transferring the low signal which comes from the Robot
side .
M70 X Mirror On
M70 sets X axis mirroring about the current X axis position.
M71 Y Mirror On
M71 sets Y axis mirroring about the current Y axis position.
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If a "P" value is specified then execution begins form the block with the same "N" number, otherwise it
is form the block after the subprogram call.
If an M99 is specified in the main program then the execution is form the start of the program. This is
called looping (or) nesting of one or more programs
Example: M99
M99 P10
Returns to the block with "N" value 10.
G CODES:
G Codes (Preparatory Functions) - Introduction.
Preparatory functions, called G codes, are used to determine the geometry of tool
movements and operating state of the machine controller; functions such as linear cutting
movements, drilling operations and specifying the units of measurement.
They are normally programmed at the start of a block.
A G code is defined using the following format:
G ØØ
where,
G is the address letter.
ØØ is the two digit number defining the G code.
G codes can be split into two categories-
1. Modal (retained) G codes.
A modal G code, once programmed into a block, will affect any subsequent blocks of the
program without having to be restated.
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Additionally, modal G codes are further split into groups according to their task and
function. A modal G code will remain active until another G code from the same group is
programmed into a block, or it is cancelled.
For example,
GØ1 and GØØ are modal G codes from group 1:
GØ1 X____;
Z____;
X____;
GØØ Z____;
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The GØØ code executes a non cutting movement, at a rapid feedrate, to a specific co-
ordinate position in the working area (absolute co-ordinate movement) or when a certain
distance from a previously stated position (incremental co-ordinate movement) is
programmed.
AG00 causes the tool to move to the specified position at the maximum speed.
Here the tool is moved to X 20 mm, Y 30mm, and Z - 1mm at a feed rate of 180 mm per minute.
If a positive radius is specified then the shorter arc is cut. If it is negative then the longer arc is cut.
When programming arcs, the end point of the arc is specified by the address X, Z when
stated as an absolute position, or U, W when stated as an incremental position. This arc
end point is sometimes referred to as the target position.
Using an absolute position (X, Z), the value is the dimension of the end point of the arc in
relation to the datum position of the component.
Using an incremental position (U, W), the co-ordinate of the end point is the distance the
tool moves from the start position of the arc. This can either be a plus (+) value or a
minus (-) value depending on the movement of the machine slides in relation to the start
position.
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In this example the tool is moved to X30mm and Y 20mm. The arc has a radius of 15mm.
"I" and "J" specify the arc start. If the value is 0 then it need not be specified.
Example: G03 X30 Y20 I15 J0 F80
G03 Counter - Clockwise Circular Interpolation
G03 causes counter - clockwise circular motion.
Arcs can be specified by either radius or arc centre. If a positive radius is specified then the shorter arc
is cut. If it is negative then the longer arc is cut.
Example: G03 X30 Y20 R15 F80
In this example the tool is moved to X 30 mm and Y 20mm. The arc has a radius of 15mm
"I" and "J" specify the arc centre relative to the arc st art. If the value is 0 then it need not be specified.
G04 Dwell
A Dwell of up to 500 seconds can be programmed.
This causes a delay in machining of 10 seconds. This can be used for drilling cycles.
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Example: G90
G01 X30 Y0
Example: G90
G01 X15
G91
G01 X2
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Billet Definition
This directive allows the billet in the simulation window to be given a size
The billet definition should be placed at the start of a program, after the measure has optionally been
set.
Billets Definition
Example : G21
Example: G71
EDGEMOVE X0 Y-20
Subprogram Directive
This directive allows a program with a non numeric name to be called as a subprogram.
M98 P2
Clear Directive
This directive switches the tutorial messages windows.
Example: CLEAR
Step Directive
This directive switches over to single step execution on - screen and when linked to the Fanuc machine
Example: STEP
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Sample Programs
LINEAR INTERPOLATION
Figure : 9.1
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LINEAR INTERPOLATION
TOOLDEF T2 D6
N030 G28 X0 Y0
N040 M06 T2
N070 Z5
N090 Y40
N100 X40
N110 Y-40
N120 X-40
N140 G00 Z5
N180 G00 Z5
N190 M05
N210 G28 X0 Y0
N220 M30
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Figure : 9. 2
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TOOLDEF T2 D6
N030 G28 X0 Y0
N040 M06 T2
N070 G00 Z5
N170 G00 Z5
N220 G00 Z5
N230 M05
N250 G28 X0 Y0
N260 M30
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CREATING AN ARC
Figure : 9. 3
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ARC EXPLANATION
TOOLDEF T2 D6
N030 G28 X0 Y0
N040 M06 T2
N070 G00 Z5
N160 G00 Z5
N170 M05
N190 G28 X0 Y0
N200 M30
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MIRROR IMAGING
Figure : 9. 4
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MIRROR IMAGING
TOOLDEF T2 D6
N030 G28 X0 Y0
N040 M06 T2
N070 G00 Z5
N090 M70
N110 M80
N120 M70
N130 M71
N150 M80
N160 M81
N170 M71
N190 M81
N200 G00 Z5
N210 M05
N230 G28 X0 Y0
N240 M30
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PROFILE MILLING
Figure : 9. 5
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SAMPLE PROFILE
BILLET X100 Y100 Z10
EDGEMOVE X0 Y0
TOOLDEF T2 D6
N010 G21 G94
N020 G91 G28 Z0
N030 G28 X0 Y0
N040 M06 T2
N050 M03 S2000
N060 G90 G00 X5 Y42 Z5
N070 G01 Z-1 F50
N080 G03 X4 1 Y27 R43
N090 X64 Y31 R29
N100 G01 X62 Y35
N110 G03 X80 Y49 R32
N120 X93 Y56 R36
N130 G02 X76 Y76 R26
N140 X67 Y62 R30
N150 X59 Y70 R6
N160 G01 X41 Y76
N170 X35 Y69
N180 G03 X5 Y56 R43
N190 G02 X5 Y42 R8
N200 G01 Z5
N210 G00 X17 Y56
N220 G01 Z-1
N230 G01 Z5
N240 G91 G28 Z0
N250 G28 X0 Y0
N260 M05
N270 M30
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Maintenance Procedure XLMILL User Manual
While carrying out maintenance work, pay out special attention to the following items to
ensure safe and in correct procedure.
Before starting any maintenance work, define the task and obtain the information relavent to
carry out the maintenance. Defining the work period and to do the necessary work is as follows.
Main Maintenance:
Apply oil regularly in the machine for Proper Maintenance
Drain the FRL unit and compressor unit regularly.
After using the machine, clean the machine properly to avoid the dust particles which froms
an accuracy in the machine.
Allow to use work piece which is instructed by MTAB (Aluminum, Aerolic, Steel are work
pieces can be used.). Should not use the wood pieces it will spoil the machine.
Arrange for a compressor (min 100litres) in case of working with pnematic systems.
(appliable to milling machines and FMS)
Emergency Stop:
Emergency Stop is used to avoid the eradication during the processment of the machine. Sudden
stop of the machine. The user can use this emergency stop button only during the emergency
requirement period
Emergency Stop.
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The XLMILL inspection and maintenance must be carried out according to the following
schedule
General Maintenance:
Provide a proper secure place and dust free environment for installing the
machine.
Clean the machine after completion of the work.
Note:
Regular maintenance of the XLMILL increases its life and performance
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Trouble shooting XLMILL User Manual
Check whether the devices are switched ON. Check the F1 fuse; also check whether the LED
for supply, trip and enable are glowing in green, red and green to identify existence of trip due to
over current
Switch off the controller.Open the control box. Check the fuse F2 and F5 at the main fuse
bank. If the fuse seen blown, flow the fuse with the same value written on it.
Set multiple reference points so that the tool will correctly processes the work piece.
4. Suppose the XL Mill is not starting after switching ON the power supply.
Adjust Gib strip so that the head column is tightened using the gib strip adjustment screw.
Also take care that the gib strip adjustment screw is not over tightened.
The Spindle should be rotated after the tool holder is moved is to home position, so as to
prevent the damage to the work piece.
Check the machine whether the communicaion cable is properly connected(USB) or used
cables.
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Refer to the controller side layout provided and check the following Fuses F1 to F5 at the
main fuse bank as per the procedure in TABLE 1.
Table 1: XL MIL
Sl.No Fuse When to check? How to check? Problem solved
No(s). yes/no
1 Fuse F2, 1.Unable to link the Switch off the Yes/no
F5 machine. controller. Open the
control box, check the If no, please refer to
2.Denstep controller fuse F2 and F5 at the table 2, first row.
is not switched on (.L main fuse bank. If the
display is not coming) fuse seen blown,
replace the fuse with
the same value written
on it.
2 Fuse F1 1. Spindle motor is not Switch off the Yes/no
functioning controller. Open the
control box, check the If no, please refer to
fuse F1 at the main table 2, second row.
fuse bank. If the fuse
seen blown, replace
the fuse with the same
value written on it.
3 Fuse F3 1.ATC motor is not Switch off the Yes/no
functioning controller. Open the If no, consult for
control box, check the servicin.
fuse F3 at the main
fuse bank. If the fuse
seen blown, replace
the fuse with the same
value written on it.
4 Fuse F4 1. Unable to execute Switch off the Yes/no
Homing controller. Open the
control box, check the If no, please refer to
2. Control box fan and table 2, third row.
fuse F1 and F5 at the
the machine Work
main fuse bank. If the
light is not functioning. fuse seen blown,
replace the fuse with
the same value written
on it.
Refer the TABLE 2 for rectifying the problems that are answered No in Table 2
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For Reference
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Overall Layout of the machine XLMILL User Manual
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Electrical Drawings XLMILL User Manual
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Glossary XLMILL User Manual
14. Appendix
Glossary
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Parting
Operation of cutting a work piece after it has been machined to
the desired size and shape. - - - - - - - - - - - - - - - - - - - 1
Pull stud
Pull stud is used to Clamp the tool holder firmly in the machine
head. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6
Pneumatic Intensifier:
This further intensifies the pneumatic pressure - - - - - 6
Roughing
Process of removal of exess material from the work piece in a
minimum time by applying high rate of feed and heavy depth of
cut. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
Reaming
It is a Multi-tooth cutter which removes relatively small amount
of material. - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
Tapping-
Operation of cutting internal threads of small diameters using a
multipoint cutting tool called Tap. - - - - - - - - - - - - - - 1
Stabilizer
A device that produces a stabilized power output without any
fluctuations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 16
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Index XLMILL User Manual
Index
A
Add a Tool .......................................................................50
ATC (Automatic Tool Changer .......................................6
Allen Key ........................................................................3
Air Filter Regulator .........................................................12
Anti-clockwise ................................................................12
Automatically ..................................................................49
B
Billets ..............................................................................3
Billet Length ...................................................................47
Billet Width .....................................................................47
Billet Depth .....................................................................47
C
CNC Machine XLMILL control side trouble Shooting ..67
Clamping Kit ...................................................................2
Com Port Options ...........................................................51
D
DRAIN ............................................................................12
Datum ..............................................................................62
Datam Plate and Billet Clamp ........................................3
Double Ended Spanner ...................................................3
Delete a Tool ...................................................................50
E&F
Editor ..............................................................................42
Fanuc Emulated Control Programming Software ...........1
H
High visibility guard .......................................................1
Hydro Pneumatic Vice ....................................................5
Hydro Pneumatic Pressure Intensfier .............................5
Hydro pneumatic vice caring ..........................................5
Hydro Pneumatic Vice ....................................................6
L
Lubricator ........................................................................12
Load Work shift offsets ...................................................46
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M
Manufactured ..................................................................1
Machine Installation .......................................................8
Machine ..........................................................................43
Machine Settings .............................................................43
Machine File Name .........................................................45
Machine Link option .......................................................54
Machine Control Settings ...............................................50
MDI Panel .......................................................................53
O
Optional Equipments ......................................................2
Offset ...............................................................................46
Oilcan with oil ................................................................3
P&R
Pneumatic System ...........................................................12
Parameter settings ...........................................................44
Requirements for Machine Connection ..........................15
Running the Machine ......................................................57
Relevant column .............................................................48
S
Saftey Precautions ...........................................................65
Save Workshift Offsets ...................................................46
Safety Regulations ..........................................................8
Set ...................................................................................42
Simulation purpose only .................................................47
Screwdriver set ...............................................................3
Setting the tool and billet ................................................55
Simulation .......................................................................56
T&U
TOOL LENGTH .............................................................48
.Taking Tool Offset and Work Offset ..............................57
Trouble Shooting .............................................................66
Use to hold the tools in the Automatic Tool Changer ...7
UpLifting of XL Mill ......................................................8
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