Haas Toolroom Mill User manual

96-0041 Rev U
July 2010
©2010 Haas Automation, Inc.
Toolroom mill
operaTor’saddendum

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96-0041 Rev U
July 2010
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
in the shop; ying chips can seriously injure people, who may not be a safe
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: These installation recommendations are to be used in conjunction
with those in the Reference Manual. Material supplied here is
given specically for the Toolroom Mill.
elecTriciTy requiremenTs
IMPORTANT! REFER TO LOCAL CODE REQUIREMENTS BEFORE
WIRING MACHINES.
• The power source must be grounded
• Frequency range is 47-66 Hz
• Line voltage that does not uctuate more than +/-5%
• Voltage imbalance or no more than 2%
• Harmonic distortion is not to exceed 10% of the total RMS voltage
Voltage Requirements
Toolroom Mill 208 3PH / 240V 1PH ±10%
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
required to be connected to the machine chassis. This ground wire is required
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
rod adjacent to the machine cannot be used for this purpose.

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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: For Single Phase operation, only terminals L1 and L3 of the
circuit breaker are used. L2, the center connection, should be
left open.
CAUTION! Make sure the main circuit breaker is in the OFF position
BEFORE changing transformer connections.
2. T5 is a small transformer mounted on the power supply assembly next to the
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
200V. If the incoming power is 220-250 VRMS, use the 240V connection. If the
incoming power is 187-219 VRMS, use the 200V connection. Failure to use the
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-
trol cabinet. This transformer supplies Single Phase 115V power to the cabinet.
It also has two different input connections located at terminal board TB2. If
the incoming power is 187-215 VRMS, connect wire 74 to the 208V position
(center). If the incoming power is 216-250 VRMS, connect wire 74 to the 240V
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
above the main power transformer) displays the number “1”, which signies
a normal power-up sequence. Next, verify the DC bus voltage on pins 6 & 7
with a voltmeter. The voltage should read approximately 335VDC if powered
from 240V, or closer to 290V if powered from 208V. If the voltage is not at least
260VDC, call the Service Department.
5. Turn the main circuit breaker OFF by rotating its shaft counterclockwise.
Close the door, lock the latches, and turn the power back on.
Main
Circuit
Breaker
Ground
Line
L1 L2 L3

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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
to familiarize you with basic setup and operation techniques. Good machining
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
• Allow for higher rake angles
• Resists chipping
• Resists softening due to high temperatures.
Carbide
• Good resistance to high temperatures
• Lower edge strength than high-speed steel
• Different composition of carbide can result in different nishes
Ceramic
• Yields good nish
• Requires negative rake angle due to low strength
• Requires very rigid setup
• Requires high horsepower
Diamond
• Four times harder than carbide
• Can retain their cutting edge for almost the length of the tool life
• Excellent stability for close tolerance work
• Excellent nish quality
NOTE: Remember to use the highest quality tooling designed for CNC
machines to achieve the best cutting condition possible.

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Tool Wear
Tool life is dependant upon the following criteria:
• Cutting feedrate
• Tool and workpiece material
• How much material is being removed
• Proper workholding device
• Use of coolants
• Use of correct SFPM (RPM) for tool and material
Tools are subject to gradual wear from the following elements:
Abrasion (Friction and rubbing removes material from the cutter.)
Caused by:
• Friction on the outside of the cutter as it passes through the material.
Adhesion High pressure/temperatures weld small chip particles to cutter.
Caused by:
• Low cutting speed
• High feed rate
• Negative cutting geometry
• ‘Sticky’ materials such as some stainless steels and pure aluminum
• Lack of coolants
Chipping The cutting edge is broken off instead of being worn away.
Caused by:
• Excessive feed rate
• Interrupted cut
• Insert geometry too weak
• Chatter
Cratering Characterized by a smooth depression on the face of the insert.
Caused by:
• Excessive cutting speed
• Ineffective use of coolant
• Friction
• Normal wear
Oxidation
• Occurs during very high cutting temperatures
• Weakens tool tips
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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Cutting uids are best suited for soft materials such as aluminum alloys and
brass.
A good ow of cutting uid should be directed to both sides of cutter whenever
possible.
These are the most common types of cutting uids:
Emulsion (water combined with mineral oils and additives)
• Used for light to moderate machining
Cutting oils (grease or solid additives)
• Limited to slow speed and low feed conditions due to ammability
• Expensive to use
Chemical or semi-chemical uids (synthetic)
• Contain no petroleum oils
• Used for more difcult machining/grinding operations
Workpiece
The more you know about the workpiece, the better you can control the
machining process. As a general rule ask these questions:
• What is the type of metal (alloy or steel)
• Has the part undergone any special process, i.e. case hardening, treated
with additives or heat treated, etc.?
Feed Rate
Feed rate is determined by the required surface nish and cutting force. Ex-
pressed in:
• Inches or millimeters per minute
• Inches or millimeters per revolution
• Inches per tooth
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:
• Rigidity of the cutter and machine
• Machine capabilities
• Spindle horsepower

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Machine Productivity
Use the load meter as an indicator of how the machine is cutting. Speeds and
feeds should be adjusted after the initial cut. The initial cut will give an instant
read-out of the performance of the machine. If adjustment are necessary, they
should be made in 10% increments. Pay close attention to:
• Chip formation and color
• Chip load
• Monitor part and xture during the cut
• Listen for any unusual noises
Surface Finish
A good nish depends on a number of variables. The following are a number of
items to check to achieve a good nish:
• Good nish results in slower feeds and higher speeds
• Face milling produces the best nish
• Increasing the number of cutters (inserts) allow for a better nish
• Cuts should always be in the same direction
• Lighter depth of cuts will produce a better nish
• Coolants use can also affect part nish
Accuracy
Machine accuracy can be affected by a number of variables, such as:
Is the machine properly warmed up?
Holes should be center drilled rst
Check the condition of the tooling
Cutting Tool Descriptions
Drill Used to create a cylindrical hole in a work piece. Drilled holes can be
“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
center drill rst and then use a regular drill to nish the hole. The tapered walls
of the center-drilled hole will keep the regular drill straight when it begins to drill
into the work piece.
Reamer Designed to remove a small amount of material from a drilled hole.
The reamer can hold very close tolerance on the diameter of a hole, and give a
superior surface nish. The hole must be drilled rst, leaving .005 to .015 of an
inch stock on the walls of the hole for the reamer to remove.
Tap Used to create screw threads inside of a drilled hole. NOTE: Care must
be taken when using a milling machine to perform a tapping operation. For
example, the spindle speed and feed must be synchronized.
End Mill Shaped similar to a drill, but with a at bottom (end). It is used primar-
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
operator. Large work holding forces require a pneumatic or hydraulic xture.
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.
The work holding equipment also must be clean, free of debris, and have
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
vise must be set so that the clamping surfaces are parallel to the X or Y-axis of
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
indicator so it begins to register on the indicator dial. Use the jog handle to
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
parallel with the machine axis. Check the result by jogging the axis back and
fourth. You may need to do this several times. When the vise is parallel, tighten
all the bolts and check the set-up again. Adjust if necessary.

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Another common type of work holding on a milling machine is clamps. If you
have an odd shaped work piece or a large one that does not t into a mill vise,
you can clamp it directly to the mill table or xture plate using clamps. Clamps
are usually a bar type with an oval slot cut through the bar for a bolt and a
tapped hole in the bar for a jackscrew. The jackscrew is set to be slightly longer
than your work piece is tall. A small shim made of soft material .05” minimum
thickness should be placed between the jackscrew and the machine table to
prevent the screw from damaging the table when the clamp is tightened.
Set the clamp on top of the work piece and the jackscrew and shim on the
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.
Another method of getting your work piece up off the table is to make a xture
plate. The xture plate can be bolted to the machine table using tee nuts and
bolts. Drill and tap holes where the clamps need to be. Clamp your part to the
xture plate as described above.
A third method of work holding is for round, cylindrical work pieces. A chuck
with movable clamping jaws can be mounted to the machine table. The chuck
works like the small chucks on a drill press or a drill motor. A chuck key is used
to turn a screw in the side of the chuck, which moves all the clamping jaws
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.