Haas Toolroom Operation Manual Supplement v2

96-0041 Rev V

March 2012

2010 Haas Automation, Inc.

Toolroom mill

operaTors addendum

196-0041 Rev V

March 2012

1. WARRANTY

All new HAAS Toolroom Mills are warranted exclusively by the Haas

Automations (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 Operators Manual for further warranty information.

2. SAFETY

Read and Follow all safety warnings - Familiarize yourself with the

Operators Manual Safety chapter. Be aware of the other people around you

in the shop; lying 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 speciically 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 luctuate 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 signiies 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 inishes Ceramic

Yields good inish

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 inish 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 luids are best suited for soft materials such as aluminum alloys and brass.

A good low of cutting luid should be directed to both sides of cutter whenever possible.

These are the most common types of cutting luids: 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 lammability

Expensive to use Chemical or semi-chemical luids (synthetic)

Contain no petroleum oils

Used for more dificult 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 inish 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 ixture during the cut Listen for any unusual noises

Surface Finish A good inish depends on a number of variables. The following are a number of items to check to achieve a good inish: Good inish results in slower feeds and higher speeds

Face milling produces the best inish

Increasing the number of cutters (inserts) allow for a better inish

Cuts should always be in the same direction

Lighter depth of cuts will produce a better inish

Coolants use can also affect part inish

Accuracy Machine accuracy can be affected by a number of variables, such as:

Is the machine properly warmed up?

Holes should be center drilled irst 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 holes location must be held to a close tolerance, use a

center drill irst and then use a regular drill to inish 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 inish. The hole must be drilled irst, 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 lat 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 of the tools diameter.

Ball End Mill A ball end mill is a bull end mill where the corner radius is exactly

the tools 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 ixture.

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 it into a mill vise, you can clamp it directly to the mill table or ixture 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 tables 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 ixture plate. The ixture 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 ixture 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.

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5. OPERATION

power up

The mill is powered up by pressing the Power On button. Press Power Up / Restart and the mill will automatically ind home.

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

shows the X, Y and Z position of the mill as well as the spindle speed. This 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

select a sub-menu. Use the arrow keys to navigate through the variables. Key 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.

To change to full CNC mode press any of the Display keys, except Offset. A complete list of G-Codes is described in the Operators manual and includes

examples to demonstrate the use of the G-codes. Press Handle Jog to return

to the Toolroom Mill menus.

A program entered through Toolroom Mill screens is also accessible in MDI (full 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

1. To access IPS, press MDI/DNC, then PROGRM/CONVRS.

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

0 0 0

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 0

0

BOLT CIRCLE BOLT LINE SINGLE HOLE

Press START>

to run in MDI or

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 0

0

Press

to run in MDI or

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.

1. To create a new program, input the letter O followed by the desired program 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.

Use the cursor arrow keys to choose a program and press WRITE to open it.

MANUAL SETUP FACE DRILL POCKET MILLING ENGRAVING VQC

CENTER DRILL

CENTER DEPTH

CENTER PECK

DRILL TOOL

DRILL DEPTH

DRILL PECK

TAP TOOL

TAP DEPTH

0 0 0

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 0

0

BOLT CIRCLE BOLT LINE SINGLE HOLE

Press START>

to run in MDI or

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) O000 6 (PROGRAM G)*

Choose a program by using the cursor keys and press WRITE to select.

or Enter a O followed by a new program

number and press WRITE to create.

MULTIPLE HOLES

3. Using the arrow keys, move the cursor to the desired insertion point for the 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.

2. Use the arrow keys to move the cursor to the desired insertion point for the new code. Press WRITE to insert the code.

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6. MAINTENANCE

The linear guide trucks are illed with grease at the factory. Under infrequent or light duty use the factory lube is suficient for several months. It is important 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

excessive coolant use (which washes the linear guides), will require weekly greasing - Two strokes of the supplied grease gun is suficient. Do not over 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

squeezing out of the seals.

Use a synthetic grease with an NLGI grade of 1.5 or 2.

6

Z-Axis Ballnut

Z-Axis

Linear Guide

6 5