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CNC Mill Tutorial

By: Joe Hershberger

August 06, 2003


CNC Mill Tutorial Oklahoma State University

Initialization
1) Turn on the control module.
2) Open IsoPro.

Design Import
3) File->ImportàDrill Files. <Fig. 1>
4) File->ImportàGerber Files. <Fig. 2>

Figure 1: Import Drill Files. Figure 2: Import Gerber Files – Set Precision.

Figure 3: Imported design.

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CNC Mill Tutorial Oklahoma State University

5) Import top layer AGAIN for use as a board outline.


6) Delete board outline from top layer and delete trace information from duplicate
top layer.
• Turn off “edit” on all other layers using the color coded display. <Fig. 4>
• Use “select tool” to select the unwanted data.
• Hit delete.

Figure 4: Layer list.

Figure 5: Additional layer with only board outline data.

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CNC Mill Tutorial Oklahoma State University

7) ViewàLayer Table. <Fig. 6>


8) Select mirror on bottom layer and board outline layer.
9) Click ‘OK’.

Figure 6: Set Bottom layer and Board Outline layer to mirror.

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CNC Mill Tutorial Oklahoma State University

Isolation
10) ToolsàIsolate (Top and Bottom layer). <Fig. 7,8>

Figure 7: Isolate layers.

Figure 8: Isolated top and bottom layers.

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CNC Mill Tutorial Oklahoma State University

11) ToolsàIsolate (Board Outline). <Fig. 9,10>

Figure 9: Isolate Board outline.

Figure 10: Isolated board outline.

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CNC Mill Tutorial Oklahoma State University

12) Delete inner isolation from board outline. <Fig. 11>


13) ViewàLayer Table. <Fig. 12>

Figure 11: Inner board outline deleted.

Figure 12: Verify the Bottom and Board Outline layers are mirrored

14) Verify bottom isolation layer and board isolation layer are “mirrored”.
15) Click ‘OK’.
16) Save an .iso file.

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CNC Mill Tutorial Oklahoma State University

Manufacturing Setup
17) MillàInitialize.
18) MillàMaterial Change.
19) Mount Board Material.
• Drill first mounting hole. <Fig. 13>
• Insert first dowel pin to align the board and the backing material. <Fig. 14>
• Drill second mounting hole while lining up the board. <Fig. 15>
• Insert the first dowel pin into the “Primary Pinning Hole” on the milling
table. <Fig. 16>

Figure 13: Drill the first mounting hole. Figure 14: Align the board and backing material
with a dowel pin.

Figure 15: Drill the second mounting hole. Figure 16: Insert the first dowel pin into the
“Primary Pinning Hole”.

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CNC Mill Tutorial Oklahoma State University

• Place board and backing material on the dowel pin in the “Primary Pinning
Hole”
• Insert second dowel pin through board and backing material into groove
for alignment. <Fig. 17>
• Tape down the board and the buffer material. <Fig. 18>

Figure 17: Place buffer material and board on Figure 18: Tape down board and buffer
dowel pins. material.

20) Align design to board.


• Zoom out and find the home position.
• Set all layers to “edit”.
• EditàSelectàAll Data. <Fig. 19>
• Offset tool bar button. <Fig. 20>

Figure 19: All layers selected to align to board material. Figure 20: Offset toolbar button

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CNC Mill Tutorial Oklahoma State University

• Drag to position design on a reasonable part on board material. <Fig. 21>

Figure 21: Board offset to fit on board material.

• EditàDeselectàAll Data.
• Verify Design Location.
i. Right click on opposite corners of the Board Outline.
ii. MachineàJump to Cursor.
iii. Verify that the machine moves from corner to corner where you
want board to be machined. <Fig. 22,23>

Figure 22: Top-Right corner verification. Figure 23: Bottom-Left corner verification.

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CNC Mill Tutorial Oklahoma State University

Drilling
21) Mill->Tool Change.
• Insert the proper drill bit. <Fig. 24>
• Set drill bit depth using spare board material as a gauge. <Fig. 25,26>

Figure 24: Insert the proper drill bit. Figure 25: Use Spare board material to set
drill bit depth.

Figure 26: Set the drill bit depth.

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CNC Mill Tutorial Oklahoma State University

• Push down on the mill head assembly and verify that pressure foot
bumper will contact the board; if not, loosen solenoid knob until it would.
• Check visually that top stop is high enough to allow drill bit to clear board.
• Press ‘OK’ (Tool will return to the previous location).
• Adjust top stop until drill bit is approximately 1/16 inch above the board.
22) Right click the drill layer in the layer list.
23) Run layer. <Fig. 27>
• Head will move to tool change.
• Verify the proper drill bit is inserted.
• Hit ‘OK’.

Figure 27: Start the drilling.

24) Repeat for each drill bit (only drill bit depth may need adjustment, other settings
will remain the same).

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CNC Mill Tutorial Oklahoma State University

Milling
25) Right click the “TOP” isolated layer.
26) Run layer.
• Set Tool ParametersàInches/min to 10 (important). <Fig. 28>
• Insert proper end mill.
• Adjust Knurl Nut so that the pressure foot bumper is below the end mill (so
that no cutting will be possible at first).
• Adjust top stop so that pressure foot bumper will clear the board.

Figure 28: Set tool parameters for milling

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CNC Mill Tutorial Oklahoma State University

• Click Jog. <Fig. 29>


i. Click Run (this will move the mill head over the board).
ii. Jog using the four directional buttons to an unused part of the
board.
iii. Click Spindle On.
iv. Click Head Down.
v. Adjust Knurl Nut (while machining) minus until end mill begins
cutting all the way through the copper layer of the board.
vi. Click Head Up.
vii. Click Spindle Off.
viii. Adjust the top stop such that the end mill bit is approximately 1/16
inch from the board material surface.
ix. Click Head Down.
x. Tighten solenoid knob until pressure foot bumper no longer applies
pressure to the board material (CW).
xi. Loosen the solenoid knob TWO full turns (CCW).
xii. Click Head Up.
xiii. Click Close.
• Hit ‘OK’ (machining will begin). <Fig. 28>

Figure 29: Jog dialog for setting mill bit

Flip Board
27) When milling the Top layer is complete, MillàMaterial Change.
28) Untape the board.
29) Flip the board (not the buffer material) maintaining the dowel pins in their
respective holes.

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CNC Mill Tutorial Oklahoma State University

Mill Bottom Layer


30) Right click Bottom Isolation layeràRun Layer.
31) Repeat milling process from above (Step 26).

Contour Routing
32) Mill->Tool Change.
33) Insert contour router bit.
34) Set mill adjustments using the same process from drilling (Step 21).
35) Right click Board Outline layeràRun Layer.
36) Select Contour Router in Tool Parameters
37) Change Tool ParametersàInches/min to 3 (important). <Fig. 30>
38) Click ‘OK’.

Figure 30: Contour route

Cleanup
39) Click MillàTool Change and remove your tool.
40) Click MillàMaterial Change.
41) Untape and remove your board and the buffer material.
42) Dispose of all tape.
43) Return the dowel pins, buffer material, and the Allen wrench to the drawer.
44) Dispose of any leftover board material.

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CNC Mill Tutorial Oklahoma State University

Reference Figures

Figure 31: Mill adjustment identification.

Figure 32: Close-up of the Head Assembly.

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CNC Mill Tutorial Oklahoma State University

Figure 33: Tools.

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