The general CNC machine setup process involves several key steps:
- Clean the Machine Table and other surfaces to verify that the machine table and fixtures are free of chips, coolant, and other debris that could interfere with operation and accuracy.
- Load Tools Load all the necessary tools for the g-code program into the machine’s tool changer, or have them readily available if your machine doesn’t have one. A CNC Setup Sheet will list the required tools and their corresponding tool numbers in the program.
- Warm up the Machine and run a spindle and machine warmup program to ensure proper lubrication and minimize thermal expansion, especially when close tolerances are important.
- Accurately set the tool length offsets in the machine’s tool table for each tool. This tells the machine the distance from the tool tip to a reference point. And Incorrect offsets can lead to collisions and damage. This information is often included in a CNC Tool Setup Sheet.
- Set Tool Diameters, and if your program uses tool compensation, check if the tool table has the correct diameter information for each cutter.
- Install workholding properly, the workholding devices, e.g., vise clamps and fixtures, needed to secure the workpiece. The CNC Setup Sheet should specify the required workholding for the job.
- Set part zero and work offsets, define the physical location of the part zero 000 coordinate on the machine, and set up any work offsets used by the program. Ideally, a CNC setup sheet includes a diagram showing where to measure part zero.
- Load the Part Program onto the machine. Transfer the correct G-code part program to the machine via USB network or other methods. It ensures you have the proper version and any necessary subprograms. The CNC Setup Sheet should indicate the program name, file name, and revision.
- Check the coolant and verify that the coolant is in good condition at the proper level and concentration, and flowing correctly to aid in chip clearing and temperature control.
- A Load Tools: Ensure the tool changer on the machine has all the tools needed by the G-code program for the part. If your machine doesn’t have an automatic tool changer, have all tools in readiness for quick manual changes. A CNC Setup Sheet Excel sheet, Spreadsheet, or setup sheet app provides all the necessary information and will list the required tools and their corresponding tool numbers in the g-code program.
- Organize tools on a tool cart or tool tray: Ensure tools are properly inserted into toolholders, observing requirements like torque specifications for ER collet chucks.
- Warm Up Machine and Spindle: Run a spindle and machine warmup program, especially when close tolerances are important. This ensures minimal thermal expansion and proper lubrication..
- Set Tool Length Offsets: Ensure the tool table on the CNC machine has the proper length offsets for all tools. The machine needs to know the distance from the tool tip to a reference the gage. Incorrect offsets can cause collisions. Some machines have an automatic Tool Length Touch Setter; otherwise, tool lengths are measured offline and entered into the Tool Table manually via the front panel, a special G-code G10 or other methods
- Set Tool Diameters: If your part program uses Tool Compensation, the machine needs the diameter of each cutter in the Tool TableInstall Workholding: Install the necessary workholding devices, vises, clamps fixtures to secure the workpiece. The CNC Setup Sheet should specify the required workholding. Ensure clean surfaces for securement and test the hold.
- Set Part Zero and Work Offsets: Tell the CNC machine the physical location of Part Zero 000 coordinate and set up any Work Offsets used by the program, useful for multiple parts or fixtures. Ideally, the CNC Setup Sheet has a diagram showing where to measure part zero.
- Load Part Program Onto the Machine: Transfer the correct g-code part program to the machine via USB network, floppy disk, paper tape (older) or RS-232 (drip feeding). Verify you have the proper version of the program, and load any necessary subprograms or library routines. Understand what the program expects from the operator e.g., optional stops as documented in the Setup Sheet.
- Check Coolant: Ensure the coolant is in good condition and operable. Check for bad smells, proper coolant level, correct concentration using a refractometer if needed, and if the coolant is being filtered. Verify that coolant is flowing freely and nozzles are aimed properly for chip clearing and potentially increased feeds and speeds.
- Running Initial Tests Dry Run: Before cutting the actual workpiece, run a test or dry run of the program in the air to visually verify the toolpath and identify potential issues. Monitor speeds and feeds.
- Verifying Accuracy and Making Adjustments: After an initial test cut on a less expensive material, if possible check the part features for accuracy. Adjust tool length offsets or cutter radius compensation in the control as needed
- Machine Inspection and Cleaning: Similar to mills, ensure the lathe is clean of chips and debris, inspect for any damage, and ensure all connections are secure.
- Loading and Managing Tools: Load the required cutting tools into the lathe’s turret or toolholders. A CNC Lathe Setup Sheet will list the necessary tools, their types, sizes, inserts, and tool positions. Ensure proper and secure installation.
- Setting Tool Offsets: Accurately set the tool offsets, defining the cutting tool tip’s position relative to a reference point. This is critical for accurate machining.
- Installing Workholding: Install the appropriate workholding device, such as a chuck or collet, to securely hold the workpiece. The Setup Sheet will specify the required clamping devices to ensure the workpiece is properly clamped.
- Setting Part Zero and Work Coordinate System: Define the machine zero and establish the work coordinate system or part zero for the workpiece. The CNC Lathe Setup Sheet should provide details on machine zeroing. For a new lathe, this may involve referencing axes.
- Loading the Part Program: Transfer the correct g-code program to the lathe’s control. Ensure you have the correct version.
- Checking Coolant: Verify the coolant system has the proper level concentration and flow.
- Pre-Operation Checks: Perform checks on the machine’s condition, including electrical and hydraulic systems, the spindle, and axis movement. For a new lathe, this includes powering up, referencing axes, and indexing the turret.
- Running Initial Tests: Dry Run the program in the air or at a slow feed rate without a workpiece to check for potential issues and verify the toolpath.
- Verifying Accuracy and Making Adjustments: After an initial cut, inspect the part for accuracy against the drawing specifications and make necessary adjustments.
Benefits of using the Setup Sheet Application
- Automation: It automates the setup process and replaces the traditional manual methods and spreadsheets with custom digital setup sheets.
- Centralized Access: Provides a single platform for all machine shop setup and tooling information.
- Customizable Structure: It offers adaptable setup sheet structures for various machining operations. You can customize the app according to your manufacturing needs.
- Tooling: Provides detailed tooling Information, including part numbers, operation sequences, tooling details with images, machine specifications, and setup instructions. It can integrate with a Tool Crib Application to automatically sync tooling information using a unique QRN number. Provides detailed tooling Information, including part numbers, operation sequences, tooling details with images, machine specifications, and setup instructions. It can integrate with a Tool Crib Application to automatically sync tooling information using a unique QRN number.
- Built-in Resources: This app includes features like a built-in speed and feed chart, a CNC programming book, and eliminates the need for external references.
- Change Tracking: It tracks modifications to set up sheets and provides a history of changes.
- Reduced Errors: It automates data input, provides clear instructions, and minimizes manual errors.
- Customization and Scalability: The application is fully customizable and scalable to meet the unique needs of each business.
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