MillMaster Pro. able of Contents. 1. Getting Started. ted. 2. Menu Descriptions

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1 Tab able of Contents 1. Getting Started ted Introduction Menu Descriptions 2.1 File Menu Switch Menu View Menu Control Menu Run Menu Tools Menu Options Menu Help Menu Function Descriptions 3.1 Function Quick Reference Function Detail Reference Configuration and Setup 4.1 Entering Part Program Information Setting the Machine Control Speed Axis Control Parameters Setting the Limit Sensors Setting the Tool Start Position Tutorial 5.1 Writing a Part Program Machining a Part Program MKEditor 6.1 Getting Started File Menu Switch Menu Edit Menu Help Menu Appendices Appendix A Keyboard Scan Code Reference Appendix B Metacommand Reference Appendix C Wiring Diagram for External Cutting Speed Control Option Appendix D Using the Configuration File Instep.cfg Document Revision: C6 MicroKinetics Corporation Page 1

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3 1 Getting Started ted With Thank you for purchasing the G-code interpreting software. This is an installation and command reference manual for. Minimum System Requirements An IBM PC XT/AT or 100% compatible MS-DOS or PC-DOS version 3.1 or later. An EGA or VGA monitor and display adaptor. A Microsoft compatible mouse. Installing on a Hard Disk With the computer turned on and at the C:\> prompt, do the following: 1. Put the diskette in drive A: 2. Type: A: 3. At the A:\> prompt, type: INSTALL Document Revision: C6 MicroKinetics Corporation Page 3

4 1 Getting Started ted With Installing on a Floppy Disk While a hard drive is recommended; it is possible to operate from a floppy disk. You will need a high density disk drive; a 1.2 Meg 5.25" or a 1.44 Meg 3.5" will do. To prepare a bootable disk perform the following: 1. Format a blank 1.2 Meg or 1.44 Meg disk using the /S option as follows: Format a: /s 2. Copy the COMMAND.COM and the MOUSE.COM files from your dos diskette to this new disk. 3. Copy all files from the supplied disk(s) to the new disk. 4. Insert the new disk and reboot by pressing the <CTRL><ALT>and<DELETE> keys simultaneously. You should see the simulation screen illustrated in Figure below. Study the items shown on the screen. Installing The Security Key Plug the security key (see Figure 1.1.1) onto a parallel port on the computer. It can be attached to either LPT1, LPT2, or LPT3. Tighten the screws using a small flathead screwdriver. Figure Security Key Starting ting **Important: will not run properly in a DOS shell under Windows. Exit Windows before running** At the DOS prompt (C:\>), type the following: CD\MCAM <ENTER> MOUSE <ENTER> MM <ENTER> Page 4 MicroKinetics Corporation Document Revision: C6

5 1 Getting Started ted With Observe the top line of the screen in Figure Each word is a heading for a pull-down menu. The pull-down menu will appear when the heading is selected by the mouse or keyboard. Pull-down Menu Headings File Program Name Control Status Figure Screen Part Dimensions Programming Format Mode Tool Position To access a pull-down menu, use the mouse to position the arrow on top of a pull-down menu heading and click the left mouse button. Alternatively, you can use the keyboard to access a pull-down menu by pressing <ALT> and the first letter of a heading. Once the menu is in view, you can select any of its options by positioning the arrow on the option and clicking the left mouse button. Document Revision: C6 MicroKinetics Corporation Page 5

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7 2 File Menu Selecting the File Menu produces the list of options shown in Figure 2.1. Some of the selections have Hot Keys associated with them. Hot keys allow quick access to a command through the keyboard and they are indicated to the right of the selection. For example, the hot key used to load a part program is <CTRL>-L which means holding down the Ctrl key and pressing L simultaneously. The letters in reverse or other color than the rest of the option text are called QuickSelect keys. These allow access to a command only while the pull-down menu is displayed. File-New Clears the part program in memory and establishes the standard defaults for a new part program. Figure 2.1 File-Load Displays the Dialog Window shown in Figure which displays all part programs in the current directory. Just double click on the file name to load it. Figure Load File Dialog Window Document Revision: C6 MicroKinetics Corporation Page 7

8 2 File Menu File-Save Quickly saves the current part program to disk. The extension CNC is automatically assigned. File-Save as... Saves the current part program to disk allowing the user to rename the file. The file extension.cnc is automatically assigned. See Figure Figure 2.1 Figure Save ve As Dialog Window File-Delete Deletes an existing part program from the disk. The CNC File Selector dialog window appears and allows the user to Choose a part program in the current directory. Use the Dir/Drives box to change to other drives and directories. Choose the OK button when the correct filename appears in the File Name box. See Figure Page 8 MicroKinetics Corporation Document Revision: C6

9 2 File Menu File-Print Code Prints the current part program in memory on the printer specified in the PRINTER OPTIONS Dialog Window. File-Print Picture Prints the current graphics screen on the printer specified in the PRINTER OPTIONS Dialog Window. File-Save Picture Saves the current graphics screen to a SCREENnn.PCX file where nn is an integer from 0 to 99 and is incremented by 1 each time this option is used. The file is saved to the current directory. Figure 2.1 File-View Picture Displays a previously saved picture on the screen. The PCX File Selector Dialog Window allows the user to choose the picture to be viewed from the current directory. Use the Dir/ Drives box to change to other drives and directories. Choose the [OK] box when the correct filename appears in the File name box. See Figure Figure PCX File Selector Window Document Revision: C6 MicroKinetics Corporation Page 9

10 2 File Menu File-Dos Shell Temporarily exits to DOS allowing you to execute most DOS commands. Type EXIT at the DOS prompt to return to. File-Exit Exits and returns control to DOS. Figure 2.1 Page 10 MicroKinetics Corporation Document Revision: C6

11 2 Switch Menu The Switch Menu shown in Figure 2.2 provides access to functions that alter or modify a part program. The letters in reverse or other color than the rest of the option text are called QuickSelect keys. These allow access to a command while the pull-down menu is displayed. Figure 2.2 Switch-To MultiCAM MILL Exits and initiates MultiCAM Mill. This is an easy-to-use milling CAD/CAM software package used to automatically create part programs by simply drawing the part profile on the screen. (Refer to the MultiCAM Mill Manual for more information). Switch-To MK Editor Exits and initiates the MK editor. This is a full text editor used to create and edit part programs. (Refer to MK Editor Manual for more information). Document Revision: C6 MicroKinetics Corporation Page 11

12 2 View Menu Selecting the View Menu produces the list of options shown in Figure 2.3. Some of the selections have Hot Keys associated with them. Hot keys allow access to a command quickly through the keyboard and they are indicated to the right of the selection. For example, the Hot key used to restore the screen is <CTRL>-R. This is done by holding down the <CTRL> key and pressing R simultaneously. The letters in reverse or other color than the rest of the option text are called QuickSelect keys. These allow access to a command only while the pull-down menu is displayed. Figure 2.3 Legend Vise/Clamps Origin Marker Figure o Screen Options View-Legend Allows the user to either enable or disable displaying the X, Y, and Z coordinate system legends on the screen. When a appears next to this function, it is enabled. See Figure View-Vise/Clamps Allows the user to either enable or disable displaying the visual representation of the vise or clamps on the screen. When a appears next to this function, it is enabled. See Figure Page 12 MicroKinetics Corporation Document Revision: C6

13 2 View Menu View-Origin Marker Allows the user to either enable or disable displaying the origin marker on the screen. The origin marker indicates the zero position of each axis. When a appears next to this function, it is enabled. See Figure View-Text Window Allows the user to view the current part program in memory. This is a read only function so any editing should be done in the Edit Window or the MK Editor. Click anywhere outside the dialog window to exit the text window. See Figure Figure 2.3 Figure Text xt Window w Enabled led View-Edit Window Allows the user to insert and append lines as well as edit and delete existing lines in the current part program in memory. This option is useful to make minor changes to the part program without terminating the software. The up and down arrow keys can be used to go the previous or next line respectively. Press <Alt> and the first letter of any of the edit buttons to select that function. Example: Pressing <Alt>-I will insert a new line at the present position. (See Figure 2.3.3) Document Revision: C6 MicroKinetics Corporation Page 13

14 2 View Menu Figure 2.3 Figure Edit Window w Enabled led View-Restore Screen Redraws the screen to show the entire uncut raw stock. View-Recreate Tool Graphics Regenerates the graphic images of the tools and saves the files to disk. You should not have to use this function unless you have a graphical display error in the tools or if some of the tools do not show up on the screen. View-Color/BW Toggles between Color and Black & White. If you intend to screen dump the graphics you should change to B&W run the part and press F10 for a screen dump. Page 14 MicroKinetics Corporation Document Revision: C6

15 2 Control ol Menu The Control Menu is used to jog the tool of the machine, set up the starting position of the machine, and calibrate the machine. The letters in reverse or other color than the rest of the option text are called QuickSelect keys. These allow access to a command only while the pull-down menu is displayed. See Figure 2.4. Control-Jog Tool Allows the user to jog all three axes on the machine. Press <+> for fast speed, <-> for slow speed, or <Enter> to exit jog mode. The absolute location of the tool is shown and updated when a jog key is released. A machine must be correctly connected to use this function. Figure 2.4 Control-Init As Start Position Graphically positions the tool to the location specified in the Tool Start Position function and resets the internal counters. The current location of the tool is assumed to be in the tool start position. Control-Set New Position Graphically positions the tool to the location entered by the user and sets the internal counters to the new values. This does NOT affect the options Tool Start Position setting. Control- Return Tool to Start Graphically moves the tool to the Tool Start Position. If Machine Mode is selected, the tool will move to the tool start position. This does NOT reset the internal counters. Control-Home To Limits Moves the machine to the limit sensors indicated in the Options-Limit Sensors Dialog Box. Limit switches must be connected to use this function. Control- Reposition from Limits Automatically positions the tool at the location specified in the Tool Start Position. Limit switches must be connected to use this function. Control-Reprogram Limit Sensors Automatically locates the position of the limit sensors after tool has been moved to the Tool Start Position. Limit switches must be connected to use this function. Document Revision: C6 MicroKinetics Corporation Page 15

16 2 Control ol Menu Control-Diagnostics This allows the user to find the maximum jog and rapid traverse speeds of any or all axes on the milling machine. It is a self running test that exercises the selected axes to determine the speed limits of the machine. The maximum speeds that are found by this function can be automatically entered into the Position and Feed Speeds window. A DIAG.LOG file that contains test information is created in the current directory and is a standard text file that can be read using the MK Editor or any other text editor. This option uses the home limit switches selected in the Limit Sensors option (if <NONE> is selected for any axis, this test can not be performed for that axis). See Figure Figure 2.4 Figure Diagnostics Window Page 16 MicroKinetics Corporation Document Revision: C6

17 2 Run Menu The Run Menu is used to execute the part program. The part program can be tested graphically or it can be used to actually machine a part. The letters in reverse or other color than the rest of the option text are called QuickSelect keys. These allow access to a command only while the pull-down menu is displayed. See Figure 2.5. Run-Auto Run Executes the current part program in memory in continuous mode. Either Graphics Mode or Machine Mode must be enabled to use this option. Figure 2.5 Run-Step Mode Executes the current part program one line at a time pausing after each line. The user must press <ENTER> to execute the next program line. Either Graphics Mode or Machine Mode must be enabled to use this option. Run-Continue This is used to continue executing the part program at the current instruction. Either Graphics Mode or Machine Mode must be enabled to use this option. Run-Interactive Cmd This allows the user to enter a single program line and see the results immediately following on the screen. This option can NOT be used in Machine Mode. Run-Engrave Text This option allows engraving text. Simply type a text line to be engraved and press <Enter>. will automatically enable Graphics Mode, disable Machine Mode, and will engrave the line graphically starting at the current tool position. The G-codes produced will be appended to the end of the current part program. You may change the Size, Spacing, and Depth parameters by entering new values and pressing <Enter> after each entry. To machine, select Machine Mode and then Auto Run. Document Revision: C6 MicroKinetics Corporation Page 17

18 2 Run Menu The parameters will revert to the values shown in the screen below every time is started. Figure 2.5 Figure The Engrave ve Text xt Window The following example will engrave the word TEST starting at location X0.5 and Y0.5 and then return home. Example: 1. Select File-New 2. Select Run-Interactive and enter G01 X0.5 Y0.5 F100 and then choose [Accept]. 3. Select Run-Engrave, enter TEST then choose [OK]. 4. Select Run-Interactive and enter M25. Run-Graphics Mode Enables graphics. If a appears next to this function it is enabled and the software will graphically move the tool while the part program is being executed. Page 18 MicroKinetics Corporation Document Revision: C6

19 2 Run Menu Run-Machine Mode Enables machining. If a appears next to this function it is enabled and the software will control the machine. Observe all safety precautions before continuing machining operations. Figure 2.5 Document Revision: C6 MicroKinetics Corporation Page 19

20 2 Tools Menu Figure 2.6 Selecting the Tools Menu produces the list of options shown in Figure 2.6. The letters in reverse or other color than the rest of the option text are called QuickSelect keys. These allow access to a command only while the pull-down menu is displayed. Tools-Start Position Allows the user to specify the position of the tool at the beginning of the program. Tools-Tool Geometry Allows the user to describe the length and radius of each tool. When changing tools, Z-axis compensation will occur automatically based on the difference in tool lengths. Figure Tool ool Geometry y Setup Window Page 20 MicroKinetics Corporation Document Revision: C6

21 2 Options Menu Selecting the Options Menu produces the list of options shown in Figure 2.7. The letters in reverse or other color than the rest of the option text are called QuickSelect keys. These allow access to a command only while the pull-down menu is displayed. Options-Material Size / Setup Allows the user to enter the setup parameters. As seen in Figure 2.7.1, the user should enter the type of units that are to be used, the method of holding the stock, and where the origin is to be located. Enter the material Length, Width, and Height in the units specified. Enter the scaling factor. The scaling factor is used to scale the size of the actual part of an existing part program without changing any code. Figure 2.7 Example: If a part program milled a part that is 2.0" square with the scale factor equal to 1, then with a scale factor equal to 2, the part would be milled to a 4.0" square. Figure Material / Setup Dialog Window Document Revision: C6 MicroKinetics Corporation Page 21

22 2 Options Menu Options-Controller Type/Address Allows the user to select the type of MicroKinetics controller, Optistep Plus, Optistep, or Quickstep and set the base address, in decimal, of the controller. NOTE: The dip switch setting on the controller must correspond to the base address. See Figure Figure 2.7 Figure Controller oller Type ype Dialog Window Options - Position and Feeds Speeds Allows the user to enter the rates at which the tool will travel. Max Unramped is the maximum instantanous rate the tool can move reliably. Rapid Traverse is the rate at which the tool will travel during G00 and the maximum rate of cutting move instructions. Ramp Speed is used by the system to determine the acceleration of the stepping motors. Fast Jog Speed is the rate the machine will travel in the Jog Mode after the + key is pressed on the keypad. Slow Jog Speed is the rate the machine will travel in the Jog Mode after the - key is pressed on the keypad. The " * " next to User Programmed Cut Speed or External Cut Speed Control (for use with an Optistep Plus controller only) indicates which cut speed mode is enabled. Page 22 MicroKinetics Corporation Document Revision: C6

23 2 Options Menu User Programmed Cut Speed mode uses the feedrate (F) codes embedded in the part program to set the cutting speed and External Cut Speed Control mode uses an external pulse to regulate the cutting speed. Rapid Traverse moves are not affected by this option. See the wiring diagram in Appendix C for instructions on how to hook-up the Optistep Plus for the External Cut Speed Control option. See Figure Figure 2.7 Figure Control ol Speeds Dialog Window Options-Control Parameters Allows the user to enter the parameters that describe the lead screw pitch, the axis polarity, and the number of logical steps per stepper motor revolution. NORMAL axis polarity is defined as when the stepper motor rotates CCW, as viewed from the motor end, it generates a positive linear move. REVERSE axis polarity generates a negative linear move under the same cicumstances. Note: If REVERSE is selected for any axis, then the limit sensor connections must also be reversed (i.e. connect a positive limit switch to the negative input). Logical step per revolution is the number of step pulses required to move the stepping motor one full revolution taking into account the motor driver resolution setting. See Figure Example: Motor Res. Driver Res. Logical Steps/Rev 200 FULLSTEP HALFSTEP 400 Document Revision: C6 MicroKinetics Corporation Page 23

24 Options Menu 2 Figure " X- Y+ 0,0-1.3" X+ Figure Axis Control ol P Parameter arameters Window Options-Limit Sensors Allows the user to select the limit switches that will be used to home to by selecting a (+) or (-) for each axis. Figure shows a typical orientation of limit sensors. Enter the position of the home limit sensor for each axis in reference to the origin of the part. On the Z-axis only, enter the position of the bottom of the tool holder in reference to the origin of the part. See Figure Y- HEADSTOCK Figure Figure Limit Sensors Window Page 24 MicroKinetics Corporation Document Revision: C6

25 2 Options Menu Options-Jog Keys Assignment Allows the user to choose which keys on the computer keyboard control thejog movement of the machine. The default sets the Z-axis to jog UP when <U> is depressed and DOWN when <D> is depressed, the X-axis to work from the left and right arrow keys, and the Y-axis to work from the up and down arrow keys. If you wish to change the jog keys, you should refer to Appendix A to obtain the key scan code for the desired key and enter into the key assignment dialog window. See Figure Figure 2.7 Figure Jog K Key y Assignment Window Options-Printer Options Allows the user to select the type of printer to be used and which port it is connected to on the computer. See Figure Document Revision: C6 MicroKinetics Corporation Page 25

26 2 Options Menu Figure 2.7 Figure Printer Options Window Options-Save As Default Saves the current settings to the default configuration file. All the options as set will become permanent. Options-Revert to Saved Defaults Clears the current settings and restores the defaults from disk. Options-Load Setup Allows the user to load a setup file. A setup file has a.mps filename extension and configures with the setup parameters in the file. This allows the user to quickly change between different setups. See Figure Page 26 MicroKinetics Corporation Document Revision: C6

27 2 Options Menu Figure 2.7 Figure Setup File Select Window Options-Save Setup Saves the current setup parameters to the current setup file. Options-Save Setup As Allows the user to save the current setup parameters to a setup file. See Figure Figure Save ve Setup As Window Document Revision: C6 MicroKinetics Corporation Page 27

28 Options Menu 2 Options-Material Area Colors Allows selection of colors in the material area. Select the background color, text color, etc. by clicking the mouse on the appropriate scroll bar and choose [Accept] when complete. See Figure Figure 2.7 Figure Material Color Setup Window Options-Menu & Window Area Colors Allows selection of colors in the environment. Select the menu and window colors, text colors, etc. by clicking the mouse on the appropriate scroll bar and choose [Accept] when complete. See Figure Figure Menu u / Window w Setup Page 28 MicroKinetics Corporation Document Revision: C6

29 2 Help Menu Help-General Use Help This will display a window of instructions on how to use the mouse and the keyboard to use the functions of this software. The window has a vertical scroll bar on the right. Click anywhere in the window to close the Dialog Box. Figure 2.8 Figure View w Help Window Help-Function Referencetware Revision This will display a window of all available functions and a description on how to use them. See Section 3. Help-Software Revision-Software Revision This will display the revision of the software that is currently operating. Help-Memory Usage This will display the number of lines in the current part program, the amount of available part program memory, and the total amount of conventional memory available. Document Revision: C6 MicroKinetics Corporation Page 29

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31 3 Function Quick Reference erence Preparatory Functions (G-Codes) G00 G01 G02 G03 G04 G17 G18 G19 G25 G26 G27 G28 G70 G71 G74 G75 G79 G80 G81 G82 G83 G85 G87 G89 G90 G91 G92 G95 Rapid positioning move Linear cutting move Clockwise circular cutting move Counterclockwise circular cutting move Set dwell in seconds Selects the XY plane for contouring (default) Selects the XZ plane for contouring Selects the YZ plane for contouring Execute subroutine Conditional branch Unconditional branch Set system or user defined variable to value Set inch programming (default) Set metric programming Sets single quadrant arc programming mode (default) Sets multiple quadrant arc programming mode Canned cycle for milling a deep channel Cancel canned cycle Canned cycle for drilling a hole Canned cycle for spot facing Canned cycle for deep hole drilling Canned boring cycle Canned drilling cycle with chip break Canned boring cycle with dwell Set absolute programming mode Set incremental programming mode (default) Set current tool position counters to value Chain to next part program Document Revision: C6 MicroKinetics Corporation Page 31

32 3 Function Quick Reference erence erence (Cont'd) Miscellaneous Functions (M-Codes) M00 Temporary stop M02 End of program stop M03 Spindle <ON> CW (output #1) M04 Spindle <ON> CCW (output #5) M05 Spindle <OFF> (output #1, output #5) M06 Tool change M08 Coolant <ON> (output #2) M09 Coolant <OFF> (output #2) M10 Vacuum <ON> (output #3) M11 Vacuum <OFF> (output #3) M12 Auxillary Output <ON> (output #4) M13 Auxillary Output <OFF> (output #4) M17 Return from subroutine M25 Rapid traverse to home position M39 Chuck <CLOSE> (output #6) M40 Chuck <OPEN> (output #6) M97 Wait for true input state then continue M99 Restart part program from beginning Page 32 MicroKinetics Corporation Document Revision: C6

33 3 Function Detail Reference erence G00 This function is used to rapidly locate the tool to a new location. This should only be used when no contact with the material is taking place. Example: G00 X0.1 Y-0.1 G01 This code is used to cut along the path of a straight line. A taper may be cut when both an X and a Z are used in the statement. Example: G01 X1.2 Y1 F20 G02 This is used for a two-axis circular cutting move in a clockwise direction. To perform a circular move the cutting tool is moved to the starting position before the G02 code is used. Following the G02 code the end point of the arc is expressed in two axis (X and Y). Next the distance from the circle center point to the start of the arc is given with an I and/or J specification. At least one of I and J must be specified. When an I or J is not specified it is assigned to be zero. Example: G02 X.5 Y2 J1 F10 Y+ Y+ Y+ X+ Y X Values of X and Y in Absolute (G90) Mode Y X 0,0 X+ 0,0 X+ 0,0 Values of X and Y in Incremental (G91) Mode I Values of I and J in G90 and G91 Modes J Document Revision: C6 MicroKinetics Corporation Page 33

34 3 G03 This code is used for counterclockwise cutting moves. It is used in the same way as the G02 command described above. Example: G00 X3 Y2 G03 X4 Y2.2 I.4375 F10 Y+ Y+ Y+ I J X+ Y X Values of X and Y in Absolute (G90) Mode Y X 0,0 X+ 0,0 X+ 0,0 Values of X and Y in Incremental (G91) Mode Values of I and J in G90 and G91 Modes G04 This code causes the program to pause for a set period of time during execution. A G04 followed by a D and the number of seconds of the delay. Example: G04 D1.5 /this pauses for 1.5 seconds G17 G18 G19 This code selects the XY plane for contouring. (default) After this command, all G02 or G03 calling moves will occur on the XY axes. This code selects the XZ plane for contouring.after this command, all G02 or G03 calling moves will occur on the XZ axes. This code selects the YZ plane for contouring.after this command, all G02 or G03 calling moves will occur on the YZ axes. Page 34 MicroKinetics Corporation Document Revision: C6

35 3 G25 This code causes program execution to continue at the first block of a named subroutine. Certain modal states are saved automatically and restored upon return from subroutine. These include G90/91, G74/ 75, and current program line. Example: G25 #GROOVE runs the GROOVE subroutine in the current file. G25 #SUBS.GROOVE runs the GROOVE subroutine in file SUBS.CNC in the current directory. G26 Conditional Branch: this code causes the program to jump to the specified label if the specified input is a logical zero. Note: Can be used with an Optistep-Plus controller only. Example: G26 I1 #HOLESET G27 will jump to #HOLESET when input 1 is a logical zero. Unconditional Branch: this code causes the program to jump to the specified label. Example: G27 #HOLESET G28 will jump to #HOLESET. This is used to set a variable to a desired value. The variable should be made up of letters and numbers only and must be enclosed in parentheses. Once the variable is defined, it may be used in any succeeding blocks in place of numerical constants. Example: G28 (DEPTH)=.050 /Sets the DEPTH to.050 G91 /Incremental G01 X-(DEPTH) F10 /Dig into material G00 X(DEPTH) /Rapid traverse out of material Document Revision: C6 MicroKinetics Corporation Page 35

36 3 G70 This code sets the inch programming format. This overrides the unit of measure selected in the Material Size/Setup Window. Example: G70 G71 This code sets the metric programming format. This overrides the unit of measure selected in the Material Size/ Setup Window. Example: G71 G74 This code selects the single quadrant arc programming mode(default). ( I, J & K parameters must be positive). Example: G74 G75 This code selects multiple quadrant arc programming mode. ( I, J & K parameters may be positive or negative). Example: G75 G79 Deep channel canned cycle. Mill a specified depth in a number of passes cutting in only one direction. The parameters include X & Y position of the hole, Z depth, and either Q # of passes or K depth per pass. Z should be 0.050" above material before command. Example: G00 X2 G79 X3 Y1 Z.2 Q4 will mill a channel 0.200" deep in 4 passes. G80 Cancels a canned cycle. Use this command after each CANNED cycle function. Page 36 MicroKinetics Corporation Document Revision: C6

37 3 G81 Drill canned cycle. The parameters include X & Y position of the hole, Z depth. Z should be 0.050" above material before command. Example: G81 X.5 Y.5 Z.15 will drill a hole 0.150" deep. G82 Spot facing canned cycle. The parameters include X & Y position of the hole, Z depth, and D dwell in seconds. Z should be 0.050" above material before command. Example: G82 X.5 Y.5 Z.2 D.5 will spot face a hole 0.200" deep and wait 1/2 second. G83 Deep hole drilling canned cycle. The parameters include X & Y position of the hole, Z final depth, and either Q # of passes or K depth per pass. Z should be 0.050" above material before command. Example: G83 X.5 Y.5 Z1 Q4 will drill a hole 1.000" deep in 4 passes. G85 Boring canned cycle. The parameters include X & Y position of the bore, Z final depth. Upstroke is at feedrate. Z should be 0.050" above material before command. Example: G85 X.5 Y.5 Z.2 will bore 0.200" deep. Document Revision: C6 MicroKinetics Corporation Page 37

38 G87 3 Drill canned cycle with chip breaking. The parameters include X & Y position of the hole, Z final depth, and either Q # of strokes or K depth per stroke. Z retracts 0.050" from the bottom of each stroke. Z should be 0.050" above material before command. Example: G87 X.5 Y.5 Z1 Q4 G87 X.5 Y.5 Z1 K.25 will drill a hole 1.000" deep in 4 passes with chip breaking. Both command lines are equivalent. G89 Boring with dwell canned cycle. The parameters include X & Y position of the bore, Z final depth. Upstroke is at feedrate. Z should be 0.050" above material before command. Example: G89 X.5 Y.5 Z.2 D.5 will bore 0.200" deep and wait 1/2 second. G90 This code Sets the absolute programming mode. In the absolute mode all positions are expressed as they relate to a single zero reference point. This code is modal and will remain in effect in the program until changed by a G91 code. The default programming mode is incremental. Example: G90 G91 This code sets the incremental programming mode. In the incremental mode all positions are given in terms of relative distance and direction from the current tool position. This code is modal and will remain in effect until changed by a G90 code. The default programming mode is incremental. Example: G91 Page 38 MicroKinetics Corporation Document Revision: C6

39 3 G92 This code sets the initial starting point of the cutting tool. This is usually used at the beginning of a program when setting the starting position, however, it may be used at any time to step and repeat a set of commands at a new location. Example: G92 X0 Z-0.05 G95 This code chains to another part programs. Include this command at the end of a part program file and it will automatically load and continue machining the specified program. Any code placed after this command will not be executed. Example: G95 #TEST will load and machine TEST.CNC out of the current directory at the end of the current file. Document Revision: C6 MicroKinetics Corporation Page 39

40 3 M00 M02 M03 M04 M05 M06 This command causes a temporary stop. Operation resumes by pressing <ENTER>. This command causes an end-of-program stop. All operations are terminated and the system returns to the main menu. This turns <ON> the spindle motor clockwise (control output #1). This turns <ON> the spindle motor counterclockwise (control output #5). This turns <OFF> the spindle motor (control output #1 and #5). This command selects the specified tool. Example: M06 T2 /selects tool #2 M08 M08 This turns <ON> the coolant (control output #2). M09 M09 This turns <OFF> the coolant (control output #2). M10 M10 This turns <ON> the vacuum (control output #3). M11 M11 This turns <OFF> the vacuum (control output #3). Page 40 MicroKinetics Corporation Document Revision: C6

41 3 M12 M12 This turns <ON> the Auxiliary Output (control output #4). This may be used to activate additional devices. M13 M13 This turns <OFF> the Auxiliary Output (control output #4). M17 M25 This command causes a return from subroutine. Must be used at the end of every subroutine. When executed this command will restore the G90/91, G74/75 status and continue from the line following the G25 subroutine call that invoked this subroutine. This command homes the Z axis, the Y axis, then the X axis. M39 M39 This <CLOSES> the chuck (control output #6). M40 M40 This <OPENS> the chuck (control output #6). M97 This command pauses part program execution until a logical zero is detected at the specified input. Note: Can be used with an Optistep-Plus controller only. Example: M97 I2 will wait for input 2 to become a logical zero before continuing program execution. M99 This command restarts execution of the part program from the beginning. Document Revision: C6 MicroKinetics Corporation Page 41

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43 4 Configuration & Setup This section will instruct you on how to configure MillMaster Pro to work with your milling machine. This section will only cover the procedures that are necessary to successfully machine a part. Enter the values as indicated below. 4.1 Entering Par art t Program Information It is necessary to enter information about your part program into so that it can accurately simulate the making of your part. Enter the values shown if you want to run the tutorial in Section Select the type of units, the fixturing method, and the location of the origin. 2. Enter the material length in the specified units. Enter 3.0. NOTE: After entering the correct value in any dialog box, the ENTER key must be pressed to accept the new value. 3. Enter the stock width in the specified units. Enter Enter the stock height in the specified units. Enter Enter the machining scale. Entering 1 means "TO SCALE" (see Option Menu section for further information). Enter Choose [ACCEPT]. Document Revision: C6 MicroKinetics Corporation Page 43

44 4 Configuration & Setup 4.2 Setting the Machine Control ol Speed The software has to know the speeds your machine can move at reliably. Choose the Options- Positions & Feed Speeds option with the mouse or type <ALT>-O N. (See Figure ) 1. Set the Max Unramped to the maximum instantanous speed at which the machine can be moved without acceleration. This speed is in steps per sec and can easily be converted from inches per minute by using the following formula: Steps/Sec = Screw Pitch x #Steps/Rev 60 The default setting is 1200 Steps/Sec and is reasonable for soft metal and plastic. 2. Set the Rapid Traverse Speed to the maximum speed at which your machine can move reliably. The default is set to 1800 Steps/Sec. You may be able to set this at a much higher rate if you are using ballscrews or other low friction mechanical drives. 3. The Ramp Speed is an acceleration parameter and is usually set for 10,000 Steps/sec/sec. You may adjust this up or down depending on your machine but it is practically set between 5,000 and 20,000. See Section 2.7 for more details. 4. Set the Fast Jog Speed to the same speed as the Max Unramped speed. 5. Set the Slow Jog Speed to a speed that can be used for fine positioning. A good value to start with is 200. Adjust the value as needed. The Control-Diagnostics option can be used to automatically find the maximum unramped and ramped speeds of your machine. Press <ALT>C D on the keyboard, select the axes to be tested, and enter the test parameters. Choose [Accept] to start the test. Page 44 MicroKinetics Corporation Document Revision: C6

45 4 Configuration & Setup 4.3 Axis Control ol Parameter arameters Choose Options - Axis Control Parameters with the mouse or type <ALT>-O X. See Figure Set the Lead Screw Pitch for both axes to the proper value for your machine. The default is 20 threads per inch (TPI). Some typical values for ballscrews and ACME threads are 5 and 10 TPI. Enter this value according to your setup. 2. Set the Logical Steps per Revolution for both axes to the proper value for your machine. The default value is 400 Steps/Rev. You can calculate this value if you know the number of degrees per step of the motor: Steps/Rev = 720(or 360 if fullstepping) # of degrees per step 3. Set the polarity of each axis. A NORMAL polarity is defined as: if the axis turns counterclockwise as viewed from the motor end, a positive cutting move will result. Set the axis to NORMAL if the above rule is true and REVERSE if it is false. Note: If reverse is selected for any axis, then the limit switch connections must also be reversed (i.e. connect a positive limit switch to the negative input). 4.4 Setting the Limit Sensors Choose Options - Limit Sensors with the mouse or type <ALT>-O L. See Figure This is to be done only if the machine your are using has limit sensors. Choose the limit sensor (either + or -) for each axis that is to be considered home. These will be the three sensors that the machine goes to in homing moves Locating the Limit Sensors 1. Locate where the absolute tool starting position is on the machine. 2. Jog the tool so that it is centered over the X & Y starting position and is raised to Z starting position height. Exit jog mode. Document Revision: C6 MicroKinetics Corporation Page 45

46 4 Configuration & Setup 3. Choose <ALT>-C I. 4. Choose <ALT>-C P. The machine will automatically move to all the limit sensors and return to the Tool Start Position. The limit sensor locations have been automatically entered into the Options-Limit Sensors dialog box. 5. Save parameters as default. This will store all your specific parameters on disk so that they automatically load at start-up. 4.5 Setting the Tool Start t Position 1. Choose Tools - Tool Start Position. Enter the absolute coordinates of where the tool will start from at the beginning of the machining process. This value should match the G92 code in the CNC program file that is to be run. Typically, the tool is centered over a corner of the stock and the Z axis is above the surface 0.050". Set the following values: X axis = 0" Y axis = 0" Z axis = 0.050" to work with the tutorial (see Figure 4.6.1). Choose [OK] when complete. These values may be changed to suit your specific needs. 4. Save parameters as default. This will store all your specific parameters on disk so that they automatically load at start-up. Congratulations, the software is now configured to your specific machine. See Section 5 for a complete tutorial. Page 46 MicroKinetics Corporation Document Revision: C6

47 5 Tutorial This section will show you how to write a part program using MK Editor and how to graphically simulate and manufacture the part using. This tutorial will touch on basic machining functions such as linear and circular cutting moves, rapid traverse moves, and homing moves. Before attempting to create and manufacture this part, your machine should be setup properly (see Section 4 - Configuration and Setup). A drawing of the part that will be produced is shown in Figure ".375" TYP. 1.5" TYP. 3.0" Figure P Par art t Drawing wing 5.1 Writing a Par art t Program From the DOS prompt type MKE and press ENTER. This will bring you to the MKE text editor. You can easily create, edit, and save your part programs. 1. Enter the first three lines. They set the programming mode, starting position and arc mode of the machine. These two commands are usually included in most part programs. The comments are optional. G90 G92 G75 /SET PROGRAMMING MODE X0 Y0 Z.050 /SET STARTING POSITION /SET MULTIPLE QUAD ARC MODE Document Revision: C6 MicroKinetics Corporation Page 47

48 5 Tutorial 2. Enter the remaining lines. M06 T3 /SELECTS TOOL #3 (END MILL) G01 Z-.312 F30 /LOWERS THE CUTTER Y3 /CUT THE FIRST FLANGE G00 Z.05 /RAISE THE CUTTER X3 G01 Z-.312 Y0 /CUT SECOND FLANGE G00 Z.05 X1.5 Y2.25 /GO TO TOP OF CIRCLE G01 Z-.312 /LOWER THE CUTTER G02 J-.75 /CUT A CW CIRCLE G00 Z.05 M06 T1 /CHANGE TO TOOL #1 /SPOT FACE 4 HOLES G82 X.375 Y.375 Z.2 D.1 Y2.625 X2.625 Y.375 G80 /CANCEL CANNED CYCLE M06 T2 /DRILL HOLES G87 X.375 Y.375 Z.61 K.1 Y X Y.375 M25 /RETURN TO HOME G74 /SET SINGLE QUAD ARC MODE M02 /END OF PROGRAM 3. Choose File-Save. Type in TUTORIAL and press <ENTER>. This will save the part program in the current directory as TUTORIAL.CNC. Some other helpful hints: 1. Optional N-Sequence Numbers. Each program line may be numbered with a Nxxxx sequence code. xxxx can be any number from 0001 to Align your code in columns. This will make it easier for you to examine other portions of your program and to refer to it in the future. 3. Add frequent comments. Especially where the command itself does not explain the operation you are performing. Page 48 MicroKinetics Corporation Document Revision: C6

49 5 Tutorial 5.2 Machining a Par art t Program Now that you've entered the part program, you will be instructed in this section on how to actually produce it. Before attempting to manufacture this part, your machine should be setup properly (see Section 4 - Configuration and Setup). The following equipment is needed for this exercise. - A magnetic chuck or parallel jaw vise. - A standard endmill cutting tool. - A center drill and a twist drill - 3" x 3" x 0.5" Stock (mild steel, plastic, wax) At the DOS prompt type MM and then <ENTER>. The screen shown in Figure should be on your screen. Figure o Graphical Screen Document Revision: C6 MicroKinetics Corporation Page 49

50 5 Tutorial Figure Choose Options-Material Size/Setup. Check that the options and values are set as follows: Units = Inch Fixturing Method = Magnetic Chuck Origin 0,0 = Left,Front,Top Length = 3.000" Width = 3.000" Height = 0.500" Machining Scale = 1 Save these parameters as default. See Figure Choose File-Load with the mouse or <ALT>-F L from the keyboard. Select TUTORIAL.CNC and choose [OK]. The program file is now loaded into. Figure Choose Run-Auto Run with the mouse or <ALT>-R A from the keyboard. This runs the turning simulation program. You should see the tool cutting the stock as the program lines scroll at the bottom of the screen. Press the <space-bar> after a few lines have executed to pause the simulation. In the dialog box choose the [STEP] option and then [RESUME]. You are now in STEP mode, hit <ENTER> and the next program line will be executed. See Figure This is a useful tool in troubleshooting a programming problem. Hit the <space-bar> again and choose [AUTO] and then [RESUME]. The part program should be free running again. Once it has completed running, it should look like Figure Page 50 MicroKinetics Corporation Document Revision: C6

51 5 Tutorial Figure Tutorial CNC Simulation If the your screen does not look like Figure 5.2.4, use MK Editor to check and edit the CNC part program. 4. Choose Run-Machine Mode with the mouse or <ALT>-R M from the keyboard. Note that the status line at the bottom of the screen indicates machine mode. 5. If you have limit sensors on your machine, choose Control-Auto Position Tool. This will automatically move your tool to the start position. If you do NOT have limit sensors, jog your tool to the start position. 6. Choose Run-Auto Run again. will now produce the part. NOTE: The <space-bar> will pause the machining process at any time. If something starts going wrong during machining, PRESS THE EMERGENCY STOP button on your machine. Document Revision: C6 MicroKinetics Corporation Page 51

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53 6 Getting Started ted With MK Editor Observe the top line of the screen in Figure 6.1. Each word is a heading for a pull-down menu. The pull-down menu will appear once the heading is selected by the mouse or keyboard. To access a pull-down menu, use the mouse to position the arrow on top of a pull-down menu heading and click the left mouse button. Alternatively, you can use the keyboard to access a pull-down menu by pressing <ALT> and the first letter of a heading. Pull-down Menu Headings Part Program Name Ruler Figure 6.1 MK Editor Screen Horizontal Scroll Bar Vertical Scroll Bar Document Revision: C6 MicroKinetics Corporation Page 53

54 6 MKEditor File Menu Selecting the File Menu produces the list of options shown in Figure 6.2. Some of the selections have Hot Keys associated with them. Hot keys allow access to a command quickly through the keyboard and they are indicated to the right of the selection. For example, the Hot key used to load a drawing is <CTRL> L which means holding down the Ctrl key and pressing L simultaneously. The letters in reverse or other color than the rest of the option text are called QuickSelect keys. These allow access to a command only while the pull-down menu is displayed. File-New Clears the part program in memory. Figure 6.2 File-Load Displays the dialog box shown in Figure which displays all part programs in the current directory. Just double click on the file name to load it. Use the Dir/Drives box to change to other drives and directories. Choose [OK] when the correct filename appears in the filename box. Figure CNC File Selection Window Page 54 MicroKinetics Corporation Document Revision: C6

55 6 MKEditor File Menu File-Revert to Saved Reloads the last saved version of the current drawing. File-Append CNC File Allows the user to append an existing.cnc file to the current file. This function displays the dialog box shown in Figure which displays all part programs in the current directory. Just double click on the file name to append it. Use the Dir/Drives box to change to other drives and directories. Choose [OK] when the correct filename appears in the filename box. File-Save Quickly saves the current part program to disk. If the part program is a new one this command allows you to enter the name of the part program. The extension.cnc is automatically assigned Figure 6.2 File-Save as... Allows saving a part program to a new file name or disk/ directory. Selecting this menu option brings up the SAVE AS dialog window shown in Figure The extension.cnc is automatically assigned. Figure Save ve As Dialog Window Document Revision: C6 MicroKinetics Corporation Page 55

56 6 MKEditor File Menu File-Delete File Deletes an existing part program from disk. The CNC File Selector dialog window appears and allows the user to choose a part program in the current directory. Use the Dir/Drives box to change to other drives and directories. Choose [OK] when the correct filename appears in the filename box. File-Print Code Outputs the current file to LPT1. File-Dos Shell Allows the user to execute DOS commands and return to the system without leaving the system. Type EXIT at the DOS prompt to return to the MK Editor. File-Exit Quits the MK Editor program. Figure 6.2 Page 56 MicroKinetics Corporation Document Revision: C6

57 6 MKEditor Switch Menu Figure 6.3 The Switch Menu shown in Figure 6.3 provides quick access to other software provided with the system. Switch-To MultiCAM Mill Exits MK Editor TM and initiates MultiCAM Mill TM program. This is an easy-to-use milling CAD/CAM software package used to automatically create part programs by simply drawing the part profile on the screen (Refer to the MultiCAM Mill Manual for more information). Switch-To Exits MK Editor TM and initiates TM. Document Revision: C6 MicroKinetics Corporation Page 57

58 6 MKEditor Edit Menu Figure 6.4 Selecting the Edit Menu produces the list of options shown in Figure 6.4. Edit-Cut Allows the user to erase text from the work area. Highlight the text that is to be cut by pressing and holding down on the left mouse button at the start of the selection block and releasing the button when the selection is complete. Press the <Del> key. Edit-Copy Allows the user to copy text from the work area. Highlight the text that is to be copied by pressing and holding down on the left mouse button at the start of the selection block and releasing the button when the selection is complete. Press <ALT> <INS> keys simultaneously. Edit-Paste Inserts what was previously copied using the Edit-Copy command. Position the cursor where the block is to be inserted and press the <Shift> <Insert> keys simultaneously. Edit-Find Locates any text or commands in the part program. First, position the cursor at the top of the part program (or at what ever point the search is to start) then select this option. The Find dialog window will appear (See Figure 6.4.1). Enter the text to be found in the dialog box and press the <Ctrl> F keys simultaneously. The cursor will stop at the first occurrence of the specified string. Page 58 MicroKinetics Corporation Document Revision: C6

59 6 MKEditor Edit Menu Figure 6.4 Figure Find Dialog Box Edit-Repeat Find Locates the next occurrence of text found with the FIND command described above. Edit-Change Allows the user to search for specific text and replace it with new text. Position the cursor at the top of the part program (or at what ever point the search is to start) then select this option. The Change dialog window will appear. Enter the text to be found, the new text and select either [Change] to replace each entry one at a time or [Change All] to automatically replace each occurance of the Find Text (See Figure 6.4.2). Document Revision: C6 MicroKinetics Corporation Page 59

60 6 MKEditor Edit Menu Figure 6.4 Figure Search h Dialog Window Edit-Colors Allows the user to select the screen colors of MK Editor. Highlight the item to be changed and click the mouse on the foreground and background scroll bars until the desired colors are selected. Select [Accept] when complete (See Figure 6.4.3). Figure Menu u Colors s Setup Window Page 60 MicroKinetics Corporation Document Revision: C6