Cuttermasters CM-01P User manual

The CUTTERMASTER Professional
CM-01P
Operator’s Manual

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CUTTERMASTER Professional CM-01P User’s Manual
Page 2
Table of Contents
Chapter 1 The CUTTERMASTER Professional CM-01P
1.0 Introduction, Forward, Contact Information .......................... 3
1.1 Disclaimer............................................................................. 4
Health Warning: Dust ........................................................... 4
 1.2 Specications ....................................................................... 5
Theory Behind the CM-01P.................................................. 6
1.3 Set Up................................................................................... 7
1.4 Care for Your Machine.......................................................... 9
Chapter 2 The Basics
 2.1 EndMillDenition............................................................... 10
Types of Relief.................................................................... 10
Test Tools.............................................................................11
2.2 Organizing Your Grinding Project ........................................11
  Edges,MaterialandProles............................................... 12
General Approach............................................................... 12
2.3 Typical Wheels ................................................................... 13
Grinding Wheel Truing & Dressing ..................................... 13
Chapter 3 Operations
3.1 Flute OD Grind ................................................................... 16
3.2 End Mill End Grinding 11V9 Wheel .................................... 19
3.3 End Gashing....................................................................... 20
3.4 Flute Inside Grinding (gumming out) .................................. 20
3.5 End Mill End Grinding 1A1 Wheel and Center Cutting....... 20
3.6 Neck Reduction Grinds....................................................... 22
3.7 Radius Grinding Basic Set Up............................................ 23
3.8 Bull Nose End Mill Radius Grinding.................................... 24
3.9 Ball Nose End Mill Radius Grinding.................................... 27
3.10 Clearance Radius Angle Grinding ...................................... 29
Appendix KB Control Board Manual ............................................................. 31
Appendix Training Videos ............................................................................. 31

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Copyright 2017
Toycen This document may not be reproduced in whole or in part without the express written permis-
sion of Toycen Industries
Cuttermasters
2353 Ridgecrest Place
Ottawa ON K1H7V4
Canada
[phone]
[e-mail]
Toycen Corporation
808 Proctor Avenue
Ogdensburg NY 13669
U.S.A
[phone]
[e-mail]
Section 1.0: Introduction
Congratulations on purchasing your CUTTERMASTER Professional CM-01P.
The CUTTERMASTER has been the best name in bench top end mill sharpeners since 1972 and
that tradition of quality continues with the new professional version. The Cuttermaster Professional
CM-01P has been designed with new features to meet the demands of today’s prototype and pro-
ductionshopsandprovidessuperiorexibilityandeaseofusefortoolregrindingandtoolmodica-
tions.
With the CM-01P you will be able to grind the diameters and ends of standard end mills in one easy
setup. With nine working axes you will also be able to sharpen roughing end mills, reamers (circum-
ferential lands), end gashes, side and face cutters, annular drills, and countersinks. You will be able
togrindreducednecks,cylindergrindsmallrounds,grindWeldonats,andcut-offcarbideorhigh
speed steel tools.
This revolutionary product was designed and built in our own shop. If you have any questions about
this or any of our productool spindle feel free to contact us.
Forward
Contact Info
If you have any service or partool spindle requests, or questions or commentool spindle about this manual,
please feel free to call or write to us at

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Chapter One
The CUTTERMASTER Professional CM-01P
Set up and General Information
1.1 Disclaimer
The CUTTERMASTER Professional is a machine tool and as such is heavy and has large moving
partool spindle and grinding wheels rotating at high speed. These wheels are dangerous and they
emit dust, carbide and steel fragmentool spindle during the normal course of operation which are
harmful if inhaled or come into contact with skin or eyes. The manufacturer is not responsible for any
injury or death caused by this apparatus.
Upon delivery the owner of the machine assumes full responsibility for itool spindle safe operation.
Care must be taken to observe proper industrial safety precautions. Always wear suitable breathing
and eye protection when using the CUTTERMASTER Professional or any other grinding machine.
Health Warning: Dust
Tool grinding and grinding in general produces dust that is hazardous to your health and may con-
tain heavy metals. We strongly urge that you consider a dust exhaust system. You are responsible
for taking the proper precautions and/or utilizing the proper auxiliary exhaust systems to protect your
health and that of your employees.
Toycen Industries, by this advisement waives any and all responsibility for any real or alleged claims
of health damage as the result of using their equipment(s) without heed to this warning.

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1.2 Specications
Imp. Graduations: 0.001
Air Bearing Stroke: 8.5” (266mm)
Air Bearing: Standard 5C Collet
CuttingToolCapacity: 2”shank,9.8”O.D.,8.5”utelengthT-slotdimension–.800x.500x.670
Table feed graduations: 0.0005 x axis carrier travel, 9” plus manual adjustment of 6”
x Axis working space: 26.5” x5 .5”
y Axis working space: 13” x 6.5”
z Axis carrier travel: 5”
Wheel Mounts: 1¼ Wheel Mounting Hubs for standard tool grinder wheels with a 1.25”
arbor.
Wheel Hubs Separate to the motor so that custom wheel hubs can be installed if
needed.
Motortilt:   Innite
Motor: 500 Watt DC Reversing and Variable Speed
Warranty: Two Year on Motor and Control
Net weight: 225 pounds (100 kg)
Dimensions: 31 X “ x 27 Y” x 21” (not including handles) Shipping dimensions - 36” x
33” x 29”
Overview
The CUTTERMASTER Professional has been designed to accommodate a variety of needs. The
tableisalargestableatsurfacewithcarriagedriveunderneath.
This system has been designed to be easy to use and maintain. As with all machine tools care must
be taken to keep all working surfaces clean and in good repair. There are four main components to
your CUTTERMASTER Professional:
• the CUTTERMASTER Professional CM-01P Universal Base
• the Toycen Radius Air Spindle and assembly
 • theToycenInniteTwinSpindleDCMotorTowerandassembly
• the DC control
The tower and tool spindle carriages can be removed, cleaned and reinstalled very easily with the
removal of the drive bolts.
Thetoolrestisacentraltothemachinepivotandisextremelyeasytouse.Theairbearingxtures

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are precision honed and capable of grinding to close tolerances. The spindle sleeve is made from
stainless steel and the spindle itself is chrome plated steel.
The Toycen Radius Air Bearing has a 180° swivel base for radius grinding and takes standard 5C
colletool spindle with end mill holders available that can hold shank sizes up to 2”. The Toycen In-
niteTwinMotorTowerprovideseasyandaccuratepositioningofthewheelstothetoolbeingground
and allows two wheels to be set and trued allowing for the indexing of one wheel to the next which is
intended to reduce set up times. The table is cast, aged monolithic grey iron.
The DC Motor comes standard with two spindles so motor/spindle assembly tilt to positive and nega-
tive angles and rotates 360°. Cutting tool clearance angles can be adjusted as needed providing real
angle result when setting angles.
There are 9 different axes to work with for unlimited versatility. Your CM-01P grinds O.D.s (outside
diamters)andendsofstandardendmillsinonesetupwithinafewminutes.insideutes,ends
(primary and secondary), as well as roughing end mills, carbide tools, reamers, end gashes, small
roundsorreamers(circumferentiallands),reducedneckgrinds,Weldonats,carbideandHSScut
off.
Theory Behind the CM-01P DC Tower
TheoriginalCUTTERMASTERwasdesignedin1972whentheprevailingendmillswerelongerute,
HighSpeedSteel(HSS),30degreehelix,ballnose2,4,and6ute.Todayweseedifferentgeome-
tries,widespreaduseofcarbide,smallcornerradii,reducednecks,andcuttermodicationsaremore
prevalent. HSS tools can be ground until the geometry won’t run any longer and this is not the case
with carbide. Carbide fails over time or with heat, whereas steel gets dull. This being said, cutting off
and grinding ends and corner radiuses has become more important.
Most grinders have a single speed AC motor, designed to be inexpensive for the manufacturers to
produce. This is not conducive to a good tool grinding environment where conditions vary from tool to
tool. DC motors have more torque throughout their variable range of speeds allowing for deeper cuts
without heat damage to the tool, given that it is a dry grinding environment. The twin wheel head of
theCM-01PDCTowercanbeipped,reversedandspeedadjustedtosuitmostanygrindingrequire-
ment.
Onthetopicofwheels,ourwheelshavebeenspecicallydesignedfordrygrindingandgoodbal-
ance. Once you get your wheels dialed in, you can work from wheel to wheel without having to re-
mount and dial in as frequently.

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1.3 Set Up
CUTTERMASTER Professional Packing.
The feet of the CM-01P are shipped separately, install them and level the machine before use.
Important,
Tables should move freely with the handwheels.
Toycen Universal Tower Details
The Universal DC Tower is reversible, variable speed and produces ten times the torque than the
standard 1/3 HP motor (5 Foot Pounds @ 1000 rpm). This eliminates tool burning by facilitating heavy
cuts at greatly reduced RPM, cutting grinding times in half on some tools.

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The CUTTERMASTER Professional has been designed using the proven Cuttermaster Machine
base, the system is stable and allows for the use of magnetic base indicators in virtually any position.
There is no guessing when dialing-in any feed or position move. Being made from a monolithic cast
baseandmotortower,theCM-01Pabsorbsvibration.Havingsignicantmassalsomeansthatifad-
justmentsare“snug”,motorrotationandtowerpivotcanbeusedwithoutsignicanttightening.
Choose a good stable and quiet location for the machine. The CUTTERMASTER Professional is very
quiet.Levelthemachineusingalevelonthewaysandnetunewiththeadjustablefeet.
Wipe any oil off of the ways. They should be clean and dry for operation. They may be wiped down
from time to time with a WD-40 and oil mix to prevent rust.
During normal operation care should be taken to keep the carriages and leadscrews clean and free
from dust and can be done with air. The lead screws are black oxide 4140 steel with steel drive nuts.
The carriage drive nutool spindle can be easily replaced should they wear over time.
A light colored back drop helps the operator locate the grinding wheel as it approaches the tool and
also protectool spindle the ways.
Check the air spindle components and wipe them completely free from dust and oil using acetone or
a solvent that does not leave a residue. Apply air and slide the air spindle tube into the bushing on the
assembly.
Put the lock ring on the front and slide the indexing collar over the back.
Note: Always have air supplied to the air spindle when being moved or in use.
All of the tool spindle pivot cap screws are intended to be used to tension the pivot action and sta-
bility of the tool spindle mount. Any of these screws can be used to lock the rotation when required
onoperationssuchasuteendsorradialgrinds(O.D.s)andoneofthesescrewsispaintedredfor
your convenience. The pivot should be able to be locked by tightening only one screw while the other
three are snug.
Hook up shop air to the air spindle with the coiled hose provided. There must be clean dry air present
(musthaveanaiddryerontheline)itcanbeusedwithoutadditionalltrationandmoisturecontrol.
Theairspindleusesonetotwocfmat80to100psi.Aregulatorlterhasnotbeenshippedwiththe
machinewhichcanbemountednearthemachineifrequired.Thelterassemblyisnotattachedto
the air spindle because there are adjustment devices that need to be accessed and the spindle must
be free to move.

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Free up the power cables and check them for damage. Read the appendix KB Control Board Manual
before operating. The internal circuit board trim pots have been set according to our preferences.
Note: Always check all wheel mounts, angular and rotational adjustmentool spindle for suit-
able tightness prior performing a grinding operation.
1.4 Care for your Machine
Themachineshouldbekeptfreeofdustanddebrisandwhennotinusealightlmofoil(e.g.WD-
40) should be applied to unprotected metal surfaces.
The assemblies are all steel and the threads should be kept clean and dry: a periodic cleaning by
spraying with WD-40 and then blown off with compressed air will keep the lead screws in good ser-
vice. Gibs should be free of dirt and slide freely.
Using the Tool Rest Assembly
The tool rest assembly is secured from stowed position to working position using the two thumb
screwsshownintherstimage.Besurethattheatfaceonthetoolrestbariscorrectlyaligned
to register with the ends of the set screws. When the tool rest is in stowed it is best snug but not to
tighten the thumbscrews. This preventool spindle marring the bar.
Tool Rest in Park Position
Tool Rest in Working Position
Tool Rest Thumb
Screws

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Chapter Two
The Basics
2.1 End Mill Denition
Endmillsareprolesharpmillingcutters.Assuch,theyrequirecertaintreatmentwhensharpening.
These tools have a relatively small diameter in proportion to their length. Because of this long shape,
careshouldbetakenwhenholdingtoeliminatechatter,improvenishpropertiesandallowforgood
tool uniformity on the diameter. These tools also have a relatively small mass, meaning that care
should be taken by monitoring heat generated during the grinding process.
If the end mill has centers, these can be used for concentric holding. If not, the tool is generally held
byacolletattheshankendwithatoothrestsetinaspecicrelationtothewheelandtoolcenter.
This tooth/tool rest is usually placed directly at the point of contact between the wheel and the cutter,
minimizing vibration during the grinding process.
Types of Relief
End mills can be sharpened with three different types of relief on the diameter:
 • aconcave,almostatsurfaceisproducedwiththefaceofaplainwheel;
 • aatreliefsurfaceisproducedwithacupwheel.
• a radial or eccentric relief is produced by presenting the face of a plain wheel at an
  angletothecuttingaxisofahelical-utedendmillorbydressinganangleontheface
of a wheel rotating on a parallel axis.
Eccentricreliefproducesarelativelynecuttingedgefreefromminutenicksandasaresultisstron-
gerthanthoseproducedbyothermethods.Anotherbenetofthismethodofre-grindingisthata
secondary clearance is not needed. If the grinding wheel face width is maintained so that it is wider
than the relieved land (measured in an axial direction), wide primary lands are possible without dan-
geroftheheelofthelandcontactingthenishedsurfaceproducedwhentheendmilliscutting.This
is due to the fact that the clearance angle formed by the curve or angle on the wheel increases as it
progresses further from the cutting edge. Most manufacturers, however, consider it good practice to
provide a secondary clearance on end mill teeth, except on the smallest size of cutters.

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Onecautiontobeobservedifsingleclearanceisused,isthataverylightnishinggrindmustbetak-
enbecauseofthelongerlineofcontactbetweenthewheelandtheendmill.Heavynishingcutool
spindleinviteburning,causeaccuracytobesacricedandcancausethediametertobereduced
more than necessary.
Test Tools
A grinding project is like all other operations in a machine shop, in that it may be unadvisable to take
trialcutsonanishproduct.Forthisreasonitisgoodtohavesetuportestcuttingtoolskeptaside
totestanglesandnishespriortogrindingthenalproduct.
2.2 Organizing Your Grinding Project
1. Determine and separate the HSS tools from the carbide tools. Aluminum Oxide (Al2O3) wheels will
disintegrate if you try to sharpen carbide tools with them and, conversely, diamond wheels will plug up
if used to sharpen high speed steel.
2. CBN wheels can be used to excellent advantage on HSS tools, providing 50 to 100 times the life at
10 times the cost of Al2O3.CBNalsoproducesbetternishesandhigheraccuracythanAl2O3be-
cause the abrasive and bond/backing materials are thermally conductive, absorbing and dissipating
much of the heat produced.
3. Once you have separated the tools, install the correct wheel for the material you are going to
sharpenonthemachine.Generally,onewillhavebetterresultsusingthenergritwheelsandlighter
cuts versus coarser wheels and heavier cuts.
4. Organize the grinding project by separating the tools into groups by size and condition of the tool.
The tools requiring the most work should be left until last as they require more severe cutting action
andavarietyofoperationssuchasendgashingorotheradditionalendproling.
5. Sharpening tools that require heavy work involves additional setups. It is advisable to consolidate
these setups based on similarity. This method helps produce more uniform results through the job,
reduces operator fatigue from repetitive setup and setup error.
• If the end is broken and needs to be repaired, this is a special project. It is probably best
to leave these cutters to the last, as they should be cut off with a cut off wheel and then
  recongured.
• From a time point of view, be selective about which tools to repair, because it requires
keen skills and the use of different wheels such as a cut-off wheel or the use of a wheel

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  suchasa12V9or1A1toproducetheclearanceprole(gash)ontheend.
If the cutter has been too badly abused you will not be able to bring it to a satisfactory state by
re-grinding. Overuse or allowing a cutter to become too dull before re-sharpening can fatigue the
cutter material itself, as well as ruin the geometry. In this case, talk to your supervisor or the owner
of the cutter before attempting to sharpen the tool. The best option might be to just return it to the
person who ruined it, as is.
Edges, Material and Proles
The main work piece material consideration when sharpening an end mill is the relief angle at and
behind the cutting edge. The exact type of relief is generally unimportant in most cases. Harder ma-
terials require the use of a smaller relief angle, so the cutting edge has enough thickness and support
to withstand the higher cutting forces and greater heat generated during cutting.
Inhardermaterials,edgesshouldbehonedtosuittheapplication.Ahoneservestoreneandrein-
force the edge, allowing for a more uniform distribution of the stresses that break down the material
beginning at the moment of highest stress over time.
Every material has an endurance limit. When a carbide cutter is too “fatigued” it will show in chipping
andakingatthecuttingedges.Thiswillbemoreapparentinthehardermaterialssuchascarbide.
Iftheedgesandtheute(rake)facearebadlychipped,thecuttershouldbere-utedtogetinto
sound “un-fatigued” base material before putting the tool back into service (best done on a CNC).
Do not over grind the diameter to get rid of the chipped utes or the tool geometry will be
ruined, reducing tool performance. The CM-01P DC Tower has been designed to mount a variety of
wheels,severalofwhichcanbesettogrindtheuterakefacefreeofchipsandspalling.Thisproce-
dureisanacquiredskill,asitisnotaxturedoperation.Ifthetoolsareexpensiveperformancetools,
they should probably be reground on a CNC.
Finally, if the tool has been ruined through overuse it is most likely not a candidate for regrinding and
reintroduction into the same production environment from which it came (with the exception of ends,
which can be easily cut off, getting you into good material).
General Approach
Never wait until the material shows signs of fatigue to sharpen. The best approach, as far as pro-
cedure goes, is to regrind the primary relief until all of the wear has been removed, being careful to
preserve as much diameter as possible. Be careful to closely check the factory angle as you start, for
reference.

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The secondary clearance face is ground next, until the desired primary land width is obtained, again
be sure your angle is correct. The amount of material to be removed per pass must be determined by
theendmillsize,materialoradesirednishrequirement.Highspeedsteeltoolscanberoughedoff
at about 0.002” per pass without generating excessive heat, depending on the width of cut. Smaller
tools should be ground more carefully to avoid chatter and overheating. The CM-01P DC Tower, with
its high torque variable speed motor combined with new Polyimide wheels is capable of taking wide
secondary cuts in excess of 0.005” in HSS or carbide without overheating the tool.
Aftergrindingthesecondaryclearanceangleitisagoodideatoredresstheprimarywithalightnish
passtorenethecuttingedge.Neveradjustthemachineonthenishingpasses.
Alwaysgoallthewayaroundthetoolwithoutadjustmenttopreventtoolrunoutonthenalpass.
Whengrindingthetoolend,therststepisalwaystheremovalofanyfailedmaterialatthecorner.
Care should be taken that all the corner wear is removed, being careful to not overheat the tool.
Asisthecasewithdamagedutes,ifthematerialthathasbeendestroyedthroughoveruseisnot
removed, it will fail prematurely and propagate failure into the adjacent sound material.
Grinding Wheels:
The Machine has been designed for a variety of wheel mounts. With the machine there
are several spacers to t the 1.25 hubs these are to be used to space the wheels out to
best accomodate reach and adjust wheel approach.
2.3 Typical Wheels
As mentioned previously, the CM-01P DC Tower is designed to mount most typical standard tool
grinder wheels and with itool spindle variable speed high torque motor, much deeper cutool spindle
canbeaccomplishedwithoutheatdamagingthetool.Wehavedesignedwheelsspecicallyforthis
purpose. Always Use Good Wheels.
Typical Tool Grinder Wheels
For a list of our recommended industrial grinding wheels or to contact us about grinding wheels
visit https://cuttermasters.com/product-category/grinding-wheels/

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Grinding Wheel Truing & Dressing
In 2014 we realized that there were no simple braked truing devices in the market for benchtop tool
grinders so we designed one that is held in a 3/8 collet for easy set up. The spindle mounted wheel
truing device is a bit more complicated than it looks. It has three bearings in it and a 10000 RPM Des-
mond wheel that will do a great job bringing your wheel into true. Just mount it in the collet and bring
it past the wheel in such a way that it can scuff it into true. The Nylock nut should be adjusted so that
there is light resistance (ie. the wheel wont rotate freely).
Upon completion of the mechanical truing process (run out), a brake truing device, single point dia-
mond dresser, diamond nib, metal bonded wheel, or rotary diamond dresser will be used to complete
the trueing process for all bonds except plated. With one of the aforementioned devices, true until
you have achieved a reading on the indicator of 0.0005 inches. The abrasive and the bond type are
the most important criteria for deciding the type of trueing and/or dressing system to use. For trueing
only with a point contact, never in-feed more than 0.0005” (0.013mm) per pass for super abrasives
(CBN or Diamond), or more than 0.0015” (0.04mm) per pass for conventional abrasives.
Conventional abrasives (aluminum oxide and silicon carbide) can be trued and dressed at the same
time, using a single point dresser. The conventional abrasive is quite friable (friability = ease with
which an abrasive fractures). This means a quality diamond with a carat size appropriate for the di-
ameter of the wheel, thickness of the wheel and abrasive grain size should be used.

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Chapter Three
Operations
3.1 Flute Outside Diameter Grind
Primary and Secondary Clearance Angles
1)Setthemachineasshowningure4withthetoolspindleonzeroandinlinewiththexaxisways
and lock it into position. Choose the appropriate collet and chuck the tool and collet into the tool spin-
dle. Adjust the spindle collars so that you have enough stroke.
2) Set your tool rest so that it is vertically in line with the center of the tool. Next, position the tool rest
so that it touches the tool about .02” in from the outside diameter of the tool [Figure 5].
The tower should be at about 90° to the x axis (but as an alternative set up, in line with the x axis
(0°) is optional). The outer edge (wheel face) should be in line with the tool rest and the motor height
should be such that the center of the wheel is in line with the center of the tool.
Set the motor angle to the desired angle for the grind (primary or secondary). You may refer to the
Figure 4. Set up for Flute O.D. Grinding Figure 5. Tool Rest Vertical and Horizontal
Positioning

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angle chart on the front of the machine as a guide [Figure 6].
Raise or lower the motor so that the face of the wheel, at its mid point is as close as possible to the
tip of the tool rest. This is important to get the desired angle [Figure 7].
Oncethemachineattitudeisset,turnonthemotorandsetthelipoftheuteonthetoolrestupnear
the shank then bring the wheel in to gently touch the tool using the y axis feed dial.
It is advisable to set a magnetic back dial indicator on the y axis table to track the depth of cut.
When the wheel touches the tool, set the dial indicator to zero and then draw the tool on the tool rest
Figure 7. Wheel Positioning in Relation to
Tool Rest
Figure 6. CUTTERMASTER Professional Resharpening Guide
Tool Radial Features
Tool Diameter 1/8 3/16 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1-1/8 1-1/4 1-1/2 2 3
Primary Land Width 0.01 0.013 0.013 0.013 0.013 0.014 0.014 0.014 0.014 0.014 0.023 0.023 0.028 0.028 0.028 0.033 0.043
Primary Clearance Angle 22° 18° 13° 12° 12° 11° 10° 10° 10° 9° 9° 8° 8° 7° 7° 6° 5°
Secondary Clearance Angle 32° 26° 22° 22° 20° 20° 18° 18° 18° 18° 17° 16° 16° 16° 16° 14° 14°
Tool End Features
Primary Land Width 0.017 0.023 0.023 0.028 0.028 0.033 0.038 0.038 0.043 0.062 0.062 0.075 0.094 0.094 0.094 0.1 0.125
Primary Relief Angle 10° 10° 6° 6° 6° 6° 6° 6° 6° 6° 6° 6° 6° 6° 6° 6° 6°
Secondary Relief Angle 25° 25° 25° 25° 20° 20° 20° 20° 20° 20° 20° 20° 20° 20° 18° 18° 18°
End Dish (Center Clearance) 3° 3° 2° 2° 2° 2° 2° 2° 1° 1° 1° 1° 1° 1° 1° 1° 1°
Machining Hard or Tough Materials These Angles can be Decreased by 20 percent
Cuttermaster Professional End Mill Resharpening Guide
General Purpose End Mill Recomended Angles
Performance Grind - High Speed Machining - Increase Angles by 20 Percent

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past the grinding wheel slowly, at an even speed, to see if it cuts evenly and to be aware of where on
the tool the grind is placed (for example, primary or secondary angle).
Placetheseconduteonthetoolrestattheshankforthesecondgrind,usingtheleveratthetopof
thetowertoavoidthewheelasyourindextothenextute,orbypullingtheairspindleuppercarriage
y-axis feed screw towards you. Be sure to listen to see if the two grinds sound the same and look the
same. Sometimes a collet collects dirt and chucks the tool off center.
Onceyouaresatisedthatthegrindsarewhereyouintendedthem,repeattheprocessforboth
primaryandsecondaryanglesuntilnished.Notethatyouwillhavetochangethemotorelevation
when setting up to grind primary versus secondary angles in order to keep the center of the wheel at
the correct height for grinding.
y Axis Air Spindle Upper Carriage Feed Screw
Tool Indexing on the CM01P
The tool spindle upper carriage y axis is set with a spring return of .300” travel. The tower handle z
axis is designed to lift the motor straight up also about .300”.
If there is dial creep when using the z axis tighten the backlash compensator to put resistance on the
z axis lead screw rotation.

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3.2 End Mill End Grinding with an 11V9 Wheel.
Primary and Secondary Clearance angles
The tool rest is not needed for this operation as the spindle collars are tightend to completely restrict
the stroke of the spindle. Shorten the working end of the tool spindle as much as possible to reduce
deectionofthetoolspindlewhengrinding.Setthefrontcollarandtightenthetoolspindlesetscrew.
Bring the index collar up against the back of the spindle as shown in Figure 8, leaving just enough
gap so that the spindle can still rotate.
SettheCollarfora2,3,4,or6utes,dependingonthetoolbeingground.Engagetheindexpinand
tighten the collar set screw.
Puttheendmillinthecorrect5Ccolletforthetoolsizeandsettheutesperfectlyhorizontaland
tighten the collet using the collet draw tube at the end of the air spindle tube.
Set the motor angle at the desired angle for the grind, either primary or secondary. You may refer to
the angle chart on the front of the machine as a guide [Figure 6].
Raise or lower the motor so the center and edge of the wheel is in line with the tool rest. This is im-
portant to get the desired angle.
Feed across the tool to the center using the Y axis feed. Do not pass center. Retract the index pin
androtatethespindletubetotheotherutethenrepeattheprocessforboththeprimaryandsecond-
arygrind.Besuretomakealightnishpassontheprimaryof.0005orso.
Onceyou’resatisedthatthegrindsareasdesired,repeattheprocessforbothprimaryandsecon-
daNote: you will have to change the motor elevation when setting up to grind primary and secondary
angles in order to keep the center of the wheel at the correct height for grinding.
An alternate set up for ends uses a 1A1 wheel [Figure 9]. Using the outside face of the wheel, the
Figure 8. Set up for End Grinding
End Face Face Approach Figure 9. End Mill End Grinding with 1A1
Wheel.

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3.3 End Gashing
This can be done in a variety of ways with several different wheel types, the easies being the 1A1.
Care should be taken to study the end geometry before proceeding and to keep track of center.
3.4 Flute Inside Grinding (gumming out)
This is a manual operation on the CUTTERMASTER Professional and as such is meant to be used
onprolesofutetypecutterssuchashoggersorotherinterruptedcuttoolsthatrequiresharpening
frominsidetheute(taps).Thereasonisthatmaterialthatisremovedfromtheinsideoftheute
means it can no longer be relied on as a face to follow with a tooth rest .
As with Gashing, this can be done in several ways. To sharpen Hogging or serrated mills, taps and to
cleanoututefacespallingoncarbidetools,thisisaregrindprocessandassuchaltersoriginalge-
ometry. Speeds and feeds will have to be adjusted when machining resumes. By clearing out spalled
materialofftheutefaceatoolcanberesharpenedwithlessreductionofthediameter.
3.5 End Mill End Grinding With a 1A1 Wheel (Plunge)
This grinding process is the fastest way to sharpen ends and mimics contemporary small grinders.
It’sbestfortwoandfourutesandquicklyproducesprimary,secondary,centercuttingandendgash
geometry with precise repeatability.
Set up the Motor tower facing inward to grind using a 1A1 wheel. The motor is set level at 0° and the
Motor tower is rotated to 1.5° to 2° to create a dish shape in the end of the tool.
Set the Tool spindle collars as shown in Figure 9 so that there is enough stroke to pull the tool out of
the way of the wheel whey your indexing to the next flute but are still able engage the indexing pin.
Feed with the main table x axis feed. To grind the primary clearance angle set the wheel height to
about 0.5” below the center of the tool (~7°). Adjust to suit.
Plunge the tool unitl the index collar bottoms out then index to the next flute and repeat.
To grind the secondary clearance angle set the wheel height to about 1.25” below the center of the
tool (~20°). Adjust to suit.
primary and secondary angles are determined by the wheel height.