4-Axes Taig Micro Mill Computer Numerical Control (CNC)
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4-Axes CNC Micro Mill, Pre-CNC Baseline, Mach3 Interface, Path Tracing Tool, Involute Gears, Z-Offset Gage Animation, CNC Bench
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4-Axes CNC Micro Mill
Baseline configuration for the 4-axes, CNC-converted, Taig mill.
A 25MB video of a circular pocket milled in machinable plastic.
There are different methods for measuring backlash. For the Taig mill, check the
lead screw adjustable nuts for tightness.
The nuts that hold the couplers must also be snug
but over tightening will damage the bearings. Sometimes, gently
tapping the coupler with a rubber mallet before tightening, helps. Loose
couplers are a very common cause of
excessive backlash. Then, lubricate the lead screws, ways, & move the
axes multiple times prior to the check.
For a CNC machine put
a 0.0001" indicator in the
spindle.
Using your controller, set the increment to
0.0001" & continue to bump it until you load the indicator 0.003.
Then reverse the motion &
bump it 0.0001" increments
in the opposite direction until the indicator
reads 0.002.
Count the total number
of times you moved it
0.0001" to get the 0.002" reading &
subtract 10.
The remaining number is
your backlash in 0.0001.
For a manual machine, turn the crank until it reads zero
on the dial &
zero the indicator.
Then reverse the crank until the indicator moves.
Reading the dial will give you the backlash.
Pre-CNC Baseline
Pre-CNC Taig Mill with a DRO, ER-16 spindle & 12" travel table.
The DRO has since been
removed for the addition of the CNC system. The
X-axis lead screw motor was removed.
Mach3 Interface
Original Mach3 Screen Set.
More books on CNC machining.
Mach3 main screen showing among many other things, the DROs. Mach3 setup tutorial.
Clean, high resolution
screen sets & the MPG can remain displayed without covering the
Mach3 panel. Pressing the tab key toggles the Mach3 Mill Manual Pulse
Generator or
MPG mode ON & OFF. There are several errors: Tab indicators not "lighted",
spindle
spelled wrong in numerous locations, & the Simple Run tab has mirrored DRO
information.
Cap held on
using three, 2-56 set screws. The pen tip is tapered so it loosened slightly when
depressed.
It worked better than expected but a new design is used that has a
constant-diameter tip for greater accuracy.
These are traces of end mill radius off-set paths.
See
the updated tracing
tool design.
ABS plastic machines well using 2-flute carbide end mills at
5500 RPM.
Involute Gears
0.021" thick brass involute gears.
Involute gear animation.
A
4.000" height, Z-axis tool length setting gage (USA).
Z-Offset Gage Animation
Z-axis offset animation showing a " end mill being set at 4.000" above the vise
bed.
A 3.000" height offset gage.
An adjustable, brass, over-travel
stop was added so the needle can only
turn less than one revolution.
Needle-based, Z-offset gages set the mill more quickly & accurately than
illuminated or digital types.
All critical surfaces of the parts, including the round post ends, were
precision surface ground for high accuracy.
Animation showing a 2.000" tool offset height being set on the
Taig CNC Z-axis using the
MPG in step mode.
Circular pocket. See the
Turner's Cube for an
example of multiple circular pockets.
Hexagonal pocket for a die.
CNC produced 13 x 19.8mm cut-outs for five, front rack-mount
(aluminum) panel snap-in rocker switches.
Pre-CNC bench preparation (above).
To reduce their exposure to
swarf, the μATX computer, breakout board box, &
stepper motor controller
are
tucked up underneath the
bench on a high shelf.
The shelf has a 1.5-inch gap
along the back for ventilation
& cords.
The bench's side & back have been
closed off using " particle board.
The board makes a sturdy mounting surface for the shelf brackets & further
stiffens the bench.
The large
hole for the
wires is below
the shelf surface in case any debris enters from the back.
Steel anchors attach the bench to the cement wall.
The (blue) wired WAN from the house router is to the left.
The MPG added an
additional E-stop. Its springy cord
needed a strain relief clamp.
Both fans blow air outward.
Have not seen any swarf on or
inside of the electronics.
Everything is running at cool temperatures. Installed a green LED for
the breakout box power.
The CPU, LCD, opto-isolation, safety charge pump, &
pendant interfaces are protected by a computer monitored
uninterruptable power supply (UPS) while the stepper motor control circuit
is protected by a standard surge protector.
An upgraded Back-UPS ES 550 having computer monitoring
software connected via a USB.
Rotate-to-unlock style
E-stops were installed to the left
& right of the mill. The pendant has an E-stop button, too.
A compact quartz halogen goose-neck magnetic-base lamp (manual)
is attached to a metal
plate screwed to the
bench.
Stepper motor cable routings. To the right, they enter
underneath the bench edge to reduce swarf entry.
Task Light
Halogen task light. I used several electrical box
covers to give the magnet a good base to grip.
4-Axes CNC Micro Mill, Pre-CNC Baseline, Mach3 Interface, Path Tracing Tool, Involute Gears, Z-Offset Gage Animation, CNC Bench