Haas Automation Toolroom Mill Installation and operating instructions
96-0041 Rev V
March 2012
©2010 Haas Automation, Inc.
Toolroom mill
operaTor’saddendum
1
96-0041 Rev V
March 2012
1. WARRANTY
All new HAAS Toolroom Mills are warranted exclusively by the Haas
Automation’s (“Manufacturer”) limited warranty against defects in material and
workmanship for a period of one (1) year from the date of purchase, which is
the date that a machine is installed at the end user. See the Warranty section
of the Mill Operator’s Manual for further warranty information.
2. SAFETY
Read and Follow all safety warnings - Familiarize yourself with the
Operator’s Manual Safety chapter. Be aware of the other people around you
distance away. Always wear safety glasses. Initial cuts/setups should be cut at
a slower speed to reduce the possibility of tool or machine damage.
3. INSTALLATION
NOTE
with those in the Reference Manual. Material supplied here is
elecTriciTy requiremenTs
IMPORTANT! REFER TO LOCAL CODE REQUIREMENTS BEFORE
WIRING MACHINES.
Voltage Requirements
Toolroom Mill
Power Supply 40 AMP
Haas Circuit Breaker 40 AMP
If service run from elec. panel
is less than 100’ use: 1PH - 8 GA WIRE/3PH - 10 GA WIRE
If service run from elec. panel
is more than 100’ use: 1PH - 6 GA WIRE/3PH - 8 GA WIRE
WARNING!
A separate earth ground wire of the same conductor size as input power is
for operator safety and proper operation. This ground must be supplied from
the main plant ground at the service entrance, and should be routed in the
same conduit as input power to the machine. A local cold water pipe, or ground
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Machine input power must be grounded. The machine will not function properly
on ungrounded power.
The maximum voltage leg-to-leg or leg-to-ground should not exceed 260 volts.
Connecting the Toolroom Mill to Power
The Toolroom Mill can be powered from either 3 Phase
208 Wye Power (Neutral Grounded) or Single Phase
240V. In either case, a separate ground wire of the
same size as the main conductors must be provided in
the power cable.
1. With the main circuit breaker in the OFF position
(rotate the shaft that connects to the breaker counter-
clockwise), hook up the power lines to the terminals on
top of the main circuit breaker. Connect the separate
ground line to the ground bus to the left of the circuit breaker.
NOTE
left open.
CAUTION! Make sure the main circuit breaker is in the OFF position
BEFORE changing transformer connections.
main circuit breaker. This transformer has two input connectors located about
two-inches from the transformer that allow it to be connected to either 240V or
correct input connector will result in either overheating of the main contactor or
failure to reliably engage the main contactor.
3. The main power transformer is located at the bottom-right corner of the con-
It also has two different input connections located at terminal board TB2. If
position (left).
4. Turn the main circuit breaker to the ON position (rotate the shaft clockwise).
Apply power to the control by pressing the Power-On switch on the control
panel. Verify that the Fault Indicator on the 320V Power Supply (located
from 240V, or closer to 290V if powered from 208V. If the voltage is not at least
Close the door, lock the latches, and turn the power back on.
Main
Circuit
Breaker
Ground
Line
L1 L2 L3
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March 2012
leveling
The Toolroom Mill is leveled in the same manner as a VF-Series machine.
NOTE: Before any axis movement takes place, remove the shipping
bracket from the spindle and table, and remove any wooden
crating from the top of the spindle head. Severe damage will
occur if machine operation is attempted with the shipping bracket
in place.
4. MACHINING PRACTICES
This section is a general overview of basic machining practices. It is intended
practices extend tool life and in the end can save money.
Insert Selection
Although inserts are expendable it does not mean that an operator should be
careless in the setup. The following are the most common insert materials
used. Each has a description of its characteristics and common usage.
High Speed Steel
Carbide
Ceramic
Diamond
NOTE:
machines to achieve the best cutting condition possible.
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Tool Wear
Tool life is dependant upon the following criteria:
Abrasion (Friction and rubbing removes material from the cutter.)
Caused by:
Adhesion High pressure/temperatures weld small chip particles to cutter.
Caused by:
Chipping The cutting edge is broken off instead of being worn away.
Caused by:
Cratering Characterized by a smooth depression on the face of the insert.
Caused by:
Oxidation
Chemical wear: Cutter/workpiece reaction begins to corrode insert
(corrosion)
Coolant
There are a number of reasons why coolant is used in the machining process;
it is used to dissipate heat generated during machining, reduces cutter fric-
tion, and promotes chip clearance. It also allows for high speed machining and
increases tool life.
Coolant is not recommended when machining cast iron or steel, or when using
carbide cutters. Carbide cutters can withstand high temperatures but not ther-
mal shock of coolant.
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brass.
possible.
Emulsion (water combined with mineral oils and additives)
Cutting oils (grease or solid additives)
Chemical or (synthetic)
Workpiece
The more you know about the workpiece, the better you can control the
with additives or heat treated, etc.?
Feed Rate
-
pressed in:
Minimum chip thickness (chip load) is determined by the cutting force.
Maximum chip thickness (chip load) is determined by machine power and tool
design.
Spindle Speed
RPM = speed at which the tooling is turning. The mill can be commanded
in either clockwise (CW) or counterclockwise (CCW) direction. The type of
application or style of tool will usually dictate the spindle direction.
Depth of Cut
The distance the cutter penetrates the workpiece, also referred to as chip load.
This is determined by the following factors:
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Machine Productivity
Surface Finish
Accuracy
Machine accuracy can be affected by a number of variables, such as:
Is the machine properly warmed up?
Check the condition of the tooling
Cutting Tool Descriptions
Drill
“through holes” or “blind holes”. A “blind hole” is not cut entirely through a work
piece.
Center drill A small drill with a pilot point. It is used to create a small hole with
tapered walls. When a hole’s location must be held to a close tolerance, use a
of the center-drilled hole will keep the regular drill straight when it begins to drill
into the work piece.
Reamer
The reamer can hold very close tolerance on the diameter of a hole, and give a
must be
inch stock on the walls of the hole for the reamer to remove.
Tap
be taken when using a milling machine to perform a tapping operation. For
example, the spindle speed and feed must be synchronized.
End Mill -
ily to cut with the side of the tool, to contour the shape of a work piece.
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Bull End Mill A bull end mill is the same as a regular end mill except that there
is a radius on the corner where the side meets the bottom. This radius can be
up to ½ of the tool’s diameter.
Ball End Mill A ball end mill is a bull end mill where the corner radius is exactly
½ the tool’s diameter. This gives the tool a spherical shape at the end. It can be
used to cut with the side of the tool like an end mill.
Work Holding
Work holding is one of the most important elements of setting up any machine
tool. Work holding is the method of clamping the work piece to the machine.
The work piece must always be held securely before any cutting can take
place. Three basic types of work holding are used in milling operations. They
are: a mill vise, clamps, and a chuck. The type used is dependant upon how
large the cutting pressure on the workpiece is going to be. The maximum
holding pressure of a manual clamp is determined by the strength of the
Fixtures should be kept close to the center of the table in order to maintain a
rigid setup. If placed at the ends of the table, harmonic vibrations could occur.
Before placing any type of work holding on your machine table, great care must
be taken to be sure that the table is clean and free of chips and other debris.
no burrs or dings that may cause instability or damage the table. If you plan
to leave your work holding on the table for any length of time, a light coat of
rust-preventative oil will help keep your table and work holding free of rust and
corrosion.
The most common method of holding a work piece for machining is a mill vise.
The vise is attached to the mill table using tee nuts and bolts. The tee nuts
slide into the tee slots in the mill table and the bolts clamp the vise in position.
Two bolts on either side of the vise hold it in place. For precision work, the
machine travel. This is done using an indicator.
To indicate a vise parallel to a machine axis, you will need an indicator and a
magnetic base to hold it. Place the magnetic base anywhere on the bottom
of the Z-axis head or the spindle housing. Jog the machine axis to bring the
indicator tip to the clamping surface you want to indicate. Set the tip of the
move the axis you want the clamping surface to be parallel to and determine
which direction the vise needs to be moved to become parallel. If the right side
of the vise needs to be moved toward the back of the machine, tighten the bolt
on the left side of the vise to be snug and leave the bolt on the right side of the
vise loose. With a dead-blow Mallet, tap the vise until the clamping surface is
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Another common type of work holding on a milling machine is clamps. If you
are usually a bar type with an oval slot cut through the bar for a bolt and a
prevent the screw from damaging the table when the clamp is tightened.
table. Place a bolt through the slot in the clamp and screw it into a tee nut in
the table’s tee slot and tighten the bolt to increase the clamping pressure. A
series of clamps around your part should hold it in place during machining.
If you need to machine completely through the part, you will need to get the
work piece off of the table. In this case, place blocks between your work piece
and the table at the same locations where your clamps are. The blocks need to
be directly under the clamps and all the blocks need to be the same height.
A third method of work holding is for round, cylindrical work pieces. A chuck
works like the small chucks on a drill press or a drill motor. A chuck key is used
simultaneously to clamp on a round work piece.
For information on other types of work holding or more information on the types
discussed here, contact your local distributor of industrial supplies.
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5. OPERATION
power up
inTroducTion
The Haas Toolroom Mills are supplied with the Intuitive Programming System
(IPS). This is displayed once the mill is powered up and homed. This screen
programming system helps the operator set up operations such as setting tool
and work offsets, drilling and tapping cycles, circular and rectangular pocket
milling, without knowledge of G-code programming.
The control will prompt for basic machining information tool type, coordinates,
feedrate, spindle speed, depth of cut, etc. Once all information is entered, the
Toolroom mill performs the desired operation.
IPS Navigation
To navigate through the menus of the Intuitive Programming System, use the
left and right arrow keys. To select the menu press Write/Enter. Some menus
have sub-menus, which again use the left and right arrow keys and Enter to
in a variable using the number pad and press Write/Enter. To exit the menu
press Cancel. Each of the variables has help text, which is displayed once the
variable is selected.
complete list of G-Codes is described in the Operator’s manual and includes
examples to demonstrate the use of the G-codes. Press “Handle Jog” to return
to the Toolroom Mill menus.
CNC).
ips recorder
The IPS recorder provides a simple method to place G-code generated by IPS
into new or existing programs.
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operaTion
2. When the recorder is available, a message appears in red in the lower right
corner:
MANUAL
SETUP FACE
DRILL POCKET MILLING ENGRAVING VQC
CENTER DRILL
CENTER DEPTH
CENTER PECK
DRILL TOOL
DRILL DEPTH
DRILL PECK
TAP TOOL
TAP DEPTH
000
0.0000 in 0.0000 in 0.0000 in
0.0000 in 0.0000 in
WRK ZERO OFST R PLANE NUM OF HOLES
X CENTER PT
Y CENTER PT
54
DIAMETER
ANGLE
CENTER HOLE
0.0000 in 0.0000 in
0.0000 in 0.000 deg
0.2000 in
00
0
BOLT CIRCLE BOLT LINE SINGLE HOLE
Press <CYCLE START>
to run in MDI or <F4>
to record output to a
program.
MULTIPLE HOLES
3. Press F4 to access the IPS recorder menu. Choose menu option 1 or 2 to
continue, or option 3 to cancel and return to IPS. F4 can also be used to return
to IPS from any point within IPS recorder.
0.0000 in
PLANE NUM OF HOLES
IAMETER CENTER HOLE
0.0000 in
0.2000 in
00
0
Press <CYCLE
to run in MDI o
r
to record outpu
program.
IPS RECORDER F4 CANCEL
1. ) Select/Create Program
2. ) Output to current program
3. ) Cancel
IPS Recorder Menu
Menu Option 1: Select / Create Program
Select this menu option to choose an existing program in memory or to create
a new program into which the G-code will be inserted.
number and press the WRITE key. The new program is created, selected, and
displayed. Press the WRITE key once more to insert the IPS G-code into the
new program.
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2. To select an existing program, enter an existing program number using the
O format (Onnnnn), then press the WRITE key to select and open the program.
To choose from a list of existing programs, press the WRITE key without input.
MANUAL
SETUP FACE
DRILL POCKET MILLING ENGRAVING VQC
CENTER DRILL
CENTER DEPTH
CENTER PECK
DRILL TOOL
DRILL DEPTH
DRILL PECK
TAP TOOL
TAP DEPTH
000
0.0000 in 0.0000 in 0.0000 in
0.0000 in 0.0000 in
WRK ZERO OFST R PLANE NUM OF HOLES
X CENTER PT
Y CENTER PT
54
DIAMETER
ANGLE
CENTER HOLE
0.0000 in 0.0000 in
0.0000 in 0.000 deg
0.2000 in
00
0
BOLT CIRCLE BOLT LINE SINGLE HOLE
Press <CYCLE START>
to run in MDI or <F4>
to record output to a
program.
Select/Create Program F4 CANCEL
O00000 (PROGRAM A)
O00001 (PROGRAM B)
O00002 (PROGRAM C)
O00003 (PROGRAM D)
O00004 (PROGRAM E)
O00005 (PROGRAM F)
O00006 (PROGRAM G)
*
Chooseaprogram by using the cursor
keys and press WRITE to select.
or
Enter a‘O’ followed byanew program
number and press WRITE to create.
MULTIPLE HOLES
new code. Press WRITE to insert the code.
Menu Option 2: Output to Current Program
1. Select this option to open the currently selected program in memory.
new code. Press WRITE to insert the code.
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6. MAINTENANCE
that the axes are cycled to their full travel daily to coat the linear guides with
grease in order to protect the surfaces.
More severe use, such as cutting absorbent materials (such as wood), or
grease, as the excessive pressure of over-greasing or using a pneumatic or an
electrical grease gun is harmful to the seals. It is not necessary to see grease
6
Z-Axis Ballnut
Z-Axis
Linear Guide
6
54
3
X-Axis Ballnut
Y-Axis Ballnut
Y-Axis Linear Guide
X-Axis Linear
Guide
Also check the Maintenance chapter of the Operator’s manual for
additional maintenance issues.
Note that the Toolroom Mill does not have a gearbox or a TSC system; disre-
gard these maintenance sections.
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