Ain-Shams

University. Computerized Numerical

Faculty of Controlled Machines- MDP
Engineering. 483s
Design and Production
Fall2023

CNC Lap Report (1)

Student Name Student I.D

Mostafa Magdy Ragab Said 1900613

Rana Mohamed Mahmoud 2000200
Merna Lamey Baset 2001662
Rawan Mohamed Fahem 2000243
Amal Mohamed Ali 1900261
 Introduction:

CNC milling machines are powerful and versatile tools used in the manufacturing
industry to create precision parts and components. The term "CNC" stands for
Computer Numerical Control, indicating that these machines are controlled by
computer programs to execute precise machining operations. CNC milling
machines are widely employed for their ability to produce intricate and complex
shapes with high accuracy.
CNC milling machines operate based on a set of instructions provided through
CNC programming. These instructions, often written in G-code, specify the
toolpath, cutting speeds, depths, and other parameters.

Applications:
1) Precision machining:
CNC milling machines are used to create precise and intricate parts with
tight tolerances, commonly found in aerospace, automotive, and medical
industries.
2) Prototyping:
They are ideal for producing prototypes and one-off parts, allowing for quick
design iterations and testing.
3) Mass production:
In mass production, CNC milling machines provide efficiency and consistency
in producing large quantities of identical parts
4) Complex shapes:
CNC milling excels at machining complex 3D shapes and surfaces that would be
challenging or impossible with traditional machining methods

In summary, CNC milling machines play a crucial role in modern

manufacturing, offering precision, efficiency, and versatility in the production of
a wide range of components. Their integration of computer control allows for
complex and intricate machining operations, making them indispensable in
industries requiring high-quality, precise parts.
Machine 1
ANAK-MATIC-8-CNC

General details

1. Precision: The Anakmatic-8 CNC machine is known for its high precision in cutting,
milling, drilling, and shaping materials like metal, wood, and plastics with accuracy
down to micrometers.

2. Automation: It is fully automated and controlled by computer numerical control

(CNC) software, allowing for complex designs to be executed with ease.

3. Versatility: This machine can work with various materials and is commonly used in
industries such as aerospace, automotive, and electronics for both prototyping and
mass production.

4. Features: The Anakmatic-8 may include features like multiple axes of movement In 3
directions ( X,Y,Z ), ,And it is a single tool machine ,with coolant systems, and
spindle speed control for optimal performance.

5. Software Compatibility: It is compatible with a range of CAD/CAM software,

enabling precise translation of design specifications into physical objects.

6. Safety: Safety features such as emergency stop buttons, protective enclosures, and
collision detection help prevent accidents and ensure operator safety.
 7. Maintenance: Regular maintenance is essential to keep the machine running smoothly
and to prolong its lifespan , but it is not available now so there is no maintenance
applied because it is from 1989

Components
1. Control Panel: The control panel is where the operator interacts with the machine. It
includes a screen for displaying information, a keyboard for inputting commands, and
buttons for manual operation.

2. CNC Controller: This is the brain of the machine that interprets the G-code
instructions and controls the movement of the axes, spindle speed, and coolant
systems.

3. Spindle: The spindle holds the cutting tool and rotates at high speeds to perform
cutting, drilling, and milling operations on the workpiece.

4. Axes: CNC machines have multiple axes (typically three to five) that control the
movement of the cutting tool in different directions (X, Y, Z), allowing for complex
machining operations.

5. Drive Motors: These motors provide the power to move the axes and control the
position of the cutting tool accurately.

6. Tool Changer: it only have one single tool and we can reprogramming if we want to
use a different tool

7. Coolant System: To prevent overheating and prolong tool life, CNC machines often
have a coolant system that sprays coolant or lubricant on the cutting tool and
workpiece during machining.

8. Worktable: The worktable holds the workpiece securely in place during machining
operations and can move in relation to the cutting tool for multi-sided machining
2. ANAYAK VMC with ATC
The ANAYAK VMC (Vertical Machining Center) with Automatic Tool Changer (ATC) is a
high-performance CNC (Computer Numerical Control) machining center designed for
precision milling and drilling operations, especially in the aerospace, automotive, and mold-
making industries. Here’s a detailed breakdown of its main components:
1. Spindle Head (Center, Top):
The spindle head houses the main spindle motor,
which drives the cutting tools. The spindle rotates
the tool at various speeds, enabling different
machining operations such as drilling, milling,
and boring. It can move vertically (Z-axis) for
cutting depth control.
2. Automatic Tool Changer (ATC):
This machine likely has an ATC mechanism that
automatically changes tools based on the
programmed operations. It reduces manual
intervention and increases productivity by
allowing multiple tools to be stored and automatically swapped in and out as needed.
3. Control Panel (Right Side):
The control panel is where the operator programs, controls,
and monitors the machine’s functions. It includes controls for
starting/stopping the machine, setting spindle speeds, feed
rates, and selecting tools in the ATC. It often features a digital
display for real-time feedback and adjustments.

4. Enclosure Doors (Front):

The doors provide a safe, enclosed workspace that contains
metal chips, coolant, and other machining debris, preventing
them from scattering. The enclosure also helps with sound
isolation and keeps the operator safe from moving parts.

5. Table/Work bed (Inside the Machine):

This is the platform on which the workpiece is mounted. It moves along the X and Y axes,
allowing precise positioning of the workpiece under the spindle for various operations. It
may have T-slots or a vise to secure the workpiece.

6. Coolant System (Suction Drum Type):

The coolant system sprays or drips coolant onto the cutting area to keep the tool and
workpiece cool, reduce friction, and improve tool life. A suction drum system can help to
extract and filter coolant mixed with chips, recycling it back into the machine.

7. Axis Drives and Motors:

These are responsible for moving the table along the X and Y axes and the spindle along the
Z-axis. These drives and motors work in synchronization for accurate machining.

8. Electrical Cabinet (Usually behind the machine):

Houses the electrical and control components, including power supplies, circuit breakers, and
servo drives. It is essential for controlling and distributing electrical power to the entire
machine.
9. Emergency Stop Button (On Control Panel):
Provides a quick way to stop all machine operations in case of an emergency, ensuring the
safety of the operator and preventing potential damage.

Each of these components works together to allow the ANAYAK VMC to perform precise
and complex machining operations, automated with the help of the ATC and controlled
coolant system.
2.1. Automatic tool changer
In the ANAYAK VMC (Vertical Machining Center) with an Automatic Tool Changer
(ATC), the drum-style tool magazine is a crucial part of the ATC system. This magazine
typically stores a large number of tools (usually between 20 to 40 or even more), depending
on the specific machine configuration. Here’s a detailed look at its components, operation,
and suction functionality:

Drum-Style Tool Magazine

1. Design and Structure:

The drum is usually cylindrical and rotates to bring the required tool position close to the
spindle.
It is engineered to be highly durable, often made from hardened materials or alloys to
withstand the repetitive rotation and tool handling.
The drum rotates swiftly and is precisely indexed so that each tool slot aligns perfectly with
the arm that transfers tools to and from the spindle.

2. Tool Holding Mechanism:

Each slot in the drum is designed to securely hold a tool holder, such as BT or CAT taper
standards.
The slots are often equipped with spring-loaded or pneumatic locking mechanisms that
secure the tools in place during rotation, preventing any wobbling or dislodging.

3. Suction Mechanism:
In this specific ANAYAK model, the drum operates with suction to enhance tool handling
precision and cleanliness.
Suction System: The suction, or vacuum system, helps by stabilizing each tool holder in its
slot, minimizing any slight movements that could cause misalignment during high-speed
rotation.
Dust and Chip Removal: The suction system also works to remove dust, chips, and small
metal particles from the tool holder interface, ensuring the tool remains clean and accurately
seated in the spindle.
Reduced Contamination: By keeping tool holders free of debris, the suction system helps
prolong the life of the drum mechanism and prevents contamination that could affect
machining precision.

4. Operation Process:
When the CNC controller signals a tool change, the drum rotates to bring the selected tool
slot to the loading position.
The suction activates to clear any debris and stabilize the tool in the slot.
The robotic arm then picks up the tool from the drum and inserts it into the spindle, after
which the suction stops, and the drum readies the next tool.

5. Advantages of the Suction Feature:

Precision: The suction system reduces the chance of misalignment by stabilizing each tool,
resulting in precise tool loading.
Clean Operation: Keeps the drum and tool interface clean, which minimizes wear and tear
on the drum slots.
Efficiency: Reduces downtime as tools remain clean and ready for operation

2.2. Dial gauge

Used for measuring tool length
 • Overview on EMAR ECNC 6040 CM BT40 ATC:

EMAR Mills are equipped with high-quality industrial milling parts and components,
from liner guides, ball screws, high speed spindles, servo & stepper motors, drivers and
bearings to cast-iron chassis and even electrostatic paint. Without compromising quality,
this machine is unmatched in its price range.
The ECNC 6040 CM components are designed for precision, longevity and with variety of
options and accessories, which enables you to operate the machine in various applications
without further adjustments or installations. EMAR Hard-Metal mills will allow you to
work at full capacity around the clock, while maintaining consistent high precision
without limitations.
EMAR’s 4-Axis simultaneous rotary can produce complex work pieces with high
precision and without the need for further rework. ECNC 6040 M offers you a very high
equipment flexibility with low cost of ownership making it without doubt your ideal
choice for good price – performance ratio.
 • Machine parts description & its function:

1. Machine base:
The machine base of a CNC
milling machine is a sturdy and
rigid structural foundation
typically made of materials like
cast iron or welded steel. It
provides stability and support for
key components such as the
worktable, spindle, and various
motors. The base's design
minimizes vibrations during
machining, ensuring accuracy. It
incorporates
mounting points for precise alignment of components, guideways for smooth movement
along different axes, and features for effective chip management. Durable and often
equipped with adjustment mechanisms, the machine base is essential for maintaining the
machine's overall stability and performance.

2. Worktable:
The worktable is a flat and rigid surface where the
workpiece is securely mounted for machining. It is a critical
component that supports the material being worked on and
allows for precise positioning. The worktable can move
along different axes (X, Y, and Z) to facilitate the accurate
cutting or shaping of the workpiece. T-slots or other fixtures
on the table enable clamping of the workpiece, ensuring
stability during machining operations. The worktable's
design is integral to achieving accuracy and repeatability in
CNC milling processes.
3. Keyboard:
a) input CNC programs, which are
sequences of commands (G-code) that
specify the toolpath and machining
operations.
b) set various parameters such as cutting speeds, feed rates, tool offsets, and

other machining parameters.

c) controls for manual axis movements. This allows the operator to move the

machine's tool along the X, Y, and Z axes for setup or testing purposes.
d) make adjustments to tool offsets or workpiece offsets to achieve the

desired machining accuracy.

 4. Spindle:
The spindle is a crucial component responsible for holding and rotating the cutting tool.
The spindle's primary function is to execute precise and controlled movements, allowing
the cutting tool to remove material from the workpiece. The spindle may have variable
speeds and can accommodate different types of cutting tools, such as end mills or drills. It
plays a key role in determining the machining speed, accuracy, and overall performance of
the CNC milling machine. Additionally, some spindles may feature automatic tool-
changing capabilities to enhance efficiency in multi-tool operations.. BT40 refers to the
type of tool holder or spindle taper.
5. Knee :
In a CNC milling machine structure, the knee is a vertically adjustable component
positioned between the machine's column and the table.
The knee allows for the vertical movement of the milling machine's spindle. It can be
adjusted up or down, enabling the milling cutter to make precise cuts at various depths
during the machining process. This flexibility is essential for accommodating different
workpiece sizes and achieving accurate milling operations.
6. Saddle:
The saddle in a CNC milling machine structure is a movable component situated on the
knee, supporting the table.
The primary function of the saddle is to provide horizontal movement along the
machine's X-axis. It allows the milling cutter to travel laterally across the workpiece,
enabling precise and controlled machining in that direction during CNC milling
operations.

7. Guideways:
Guideways in a CNC milling machine are linear bearing surfaces that guide the
motion of machine components along defined paths.
The primary function of guideways is to provide precise and smooth linear motion for the
machine's moving parts, such as the saddle, table, or spindle. They ensure accurate
positioning of these components, contributing to the overall precision and repeatability of
the CNC milling machine. The type of guideways used (e.g., ball, roller, or hydrostatic)
influences factors such as rigidity, friction, and resistance to wear, impacting the machine's
performance and accuracy.
 8. Automatic tool changer
The Automatic Tool Changer (ATC) is a sophisticated mechanism designed to
automate the process of changing cutting tools during machining operations. It
significantly enhances efficiency and reduces downtime by eliminating the need for
manual tool changes.
 9. Tool magazine
The Tool Magazine is a storage unit designed to hold and organize a variety of cutting
tools used during machining operations. This component is an integral part of an
Automatic Tool Changer (ATC) system, enhancing efficiency by automating the tool-
changing process

10.Axes (X, Y, Z):

CNC milling machines typically have three main axes for controlling the machine's
movement. X and Y control horizontal movements, while Z controls vertical movement

11.CNC Controller
The CNC controller of a CNC milling machine is the central component responsible
for interpreting programming instructions and controlling the movement of the
machine and tool changes.
The 6040 cm cnc milling machine uses Mach3 control.
Mach3 control is a popular CNC control software used in milling machines. It serves as
the interface between a computer and the CNC machine, allowing users to program,
control, and monitor the milling process.
Mach3 interprets G-code instructions generated by CAM software, translating them into
motion commands for the CNC milling machine. It manages toolpaths, regulates spindle
speed, and controls axis movements, providing a user-friendly platform for CNC milling
operations

12.Motors and drive systems:

The 6040 cm cnc milling machine uses Closed Loop Hybrid Stepper Servo Motors.
Closed-loop hybrid stepper servo motors in CNC milling machines combine the precision
of servo motors with the simplicity of stepper motors. They feature a closed-loop system
with integrated encoders or resolvers for real-time position feedback
These motors provide high precision and accuracy by continuously adjusting motor
position based on feedback. They offer smooth operation, maintain torque at high
speeds, and correct errors in real-time, ensuring reliable and efficient toolpath execution
in CNC milling applications.

13.Limit switches
Limit switches are safety devices (Sensors) that serve to detect the physical limits of
the machine's movement along each axis (X, Y, and Z). These switches are
strategically placed at the ends of the machine's travel paths to prevent over-travel
and potential damage to the machine or workpiece.
 14.(E-Stop) button
The Emergency Stop (E-Stop) button on a CNC milling machine is a prominent safety
feature designed to immediately halt all machine movements and operations in the event of
an emergency or any situation requiring an urgent stop.

15.Coolant system
The coolant system of a CNC milling machine is an essential component designed to
manage heat generated during machining processes, enhance tool life by reducing
friction and wear., and improve the overall quality of machined parts. It also helps in chip
removal and lubrication.

16.Chip conveyor
A chip conveyor is a mechanical system designed to efficiently remove chips and debris
produced during the machining process to maintain cleanliness and prevent damage and
preventing interference with the machining process, and ensuring the longevity of the
cutting tools.

17.Lubrication system
The lubrication system is a critical component designed to reduce friction, minimize
wear and tear, and ensure the smooth operation of various moving parts within the
machine.
The primary purpose of the lubrication system is to provide a controlled and
continuous supply of lubricant (usually oil or grease) to critical moving components,
such as bearings, guideways, and ball screws. This reduces friction and heat
generation, preventing premature wear and ensuring optimal performance.

18.Tool holder:
The tool holder in a CNC milling machine is a specialized component designed to
securely grip and support cutting tools during machining operations. It plays a crucial role
in maintaining the precision and stability of the cutting process. the primary purpose of
the tool holder is to securely hold cutting tools, such as end mills, drills, or inserts, and
facilitate their accurate positioning and rotation during the machining process.
BT40 refers to the tool holder taper standard. It specifies the type of connection between
the spindle and the cutting tool.

19.Power supply
Provides electrical power to various components of the machine.
 • References:

https://www.makershop.co.nz/mach3

https://www.emar-eg.com/e6040m/
https://www.emar-eg.com/wp-content/uploads/2022/11/EMAR-Catalog-2023.pdf

Introduction to CNC Milling (uti.edu)

 Mach3 controls and running a part program

6. Mach3 controls and running a part program

This chapter is intended for reference to explain the screen controls provided
by Mach3 for setting up and running a job on the machine. It is of relevance
to machine operators and for part-programmers who are going to prove their
programs on Mach3.

6.1 Introduction
This chapter covers a lot of detail. You may wish to skim section 6.2 and then look at the
sections for inputting and editing part programs before returning to the details of all the
screen controls.

6.2 How the controls are explained in this chapter

Although at first sight you may feel daunted by the range of options and data displayed by
Mach3, this is actually organised into a few logical groups. We refer to these as Families of
Controls. By way of explanation of the term "control", this covers both buttons and their
associated keyboard shortcuts used to operate Mach3 and the information displayed by
DROs (digital read-outs), labels or LEDs (light emitting diodes).
The elements of each control family are defined for reference in this chapter. The families
are explained in order of importance for most users.
You should, however, note that the actual screens of your Mach3 does not include every
control of a family when the family is used. This may be to increase readability of a

Figure 6.1 - Screen switching control family

particular screen or to avoid accidental changes to the part being machined in a production
environment
A Screen Designer is provided that allows controls to be removed or added from the screens
of a set of screens. You can modify or design screens from scratch so that you can add any
controls to a particular screen if your application requires this. For details see the Mach3
Customisation wiki.

6.2.1 Screen switching controls

These controls appear on each screen. They allow switching between screens and also
display information about the current state of the system.

6.2.1.1 Reset
This is a toggle. When the system is Reset the LED glows steadily, the charge pump pulse
monitor (if enabled) will output pulses and the Enable outputs chosen will be active.

6.2.1.2 Labels
The "intelligent labels" display the last "error" message, the current modes, the file name of
the currently loaded part program (if any) and the Profile that is in use.

Rev 1.84-A2 6-1 Using Mach3Mill

 Mach3 controls and running a part program

Figure 6.2 - Axis control family

6.2.1.3 Screen selection buttons

These buttons switch the display from screen to screen. The keyboard shortcuts are given
after the names. For clarity in all cases when they are letters they are in upper-case. You
should not, however, use the shift key when pressing the shortcut.

6.2.2 Axis control family

This family is concerned with the current position of the tool (or more precisely, the
controlled point).
The axes have the following controls:

6.2.2.1 Coordinate value DRO

These are displayed in the current units (G20/G21) unless locked to the setup units on the
Config>Logic dialog. The value is the coordinate of the controlled point in the displayed
coordinate system. This will generally be the coordinate system of the current Work Offset
(initially 1 - i.e. G54) together with any G92 offsets applied. It can however be switched to
display Absolute Machine Coordinates.
You can type a new value into any Axis DRO. This will modify the current Work Offset to
make the controlled point in the current coordinate system be the value you have set. You
are advised to set up Work Offsets using the Offsets screen until you are fully familiar with
working with multiple coordinate systems.

6.2.2.2 Referenced
The LED is green if the axis has been referenced (i.e. is in a known actual position)
Each axis can be referenced using the Ref All button. Individual axes can be referenced on
the Diagnostics screen
♦ If no home/reference switch is defined for the axis, then the axis will not actually
be moved but, if Auto Zero DRO when homed is checked in Config>Referencing,
then the absolute machine coordinate of the current position of the axis will be set
to the value defined for the axis in the Home/Reference switch locations table in
the Config>State dialog. This is most often zero.
♦ If there is a home/reference switch defined for the axis and it is not providing an
active input when the Ref is requested, then the axis will be moved in the
Using Mach3Mill 6-2 Rev 1.84-A2
 Mach3 controls and running a part program

direction defined in Config>Referencing until the input does become active. It

then backs off a short distance so that the input is inactive. If the input is already
active then the axis just moves the same short distance into the inactive position.
If Auto Zero DRO when homed is checked in Config>Referencing then the
absolute machine coordinate of the current position of the axis will be set to the
value defined for the axis in the Home/Reference switch locations table in the
Config>State dialog.
The De-Ref All button does not move the axes but stops them being in the referenced state.

6.2.2.3 Machine coordinates

The MachineCoords button displays absolute machine coordinates. The LED warns that
absolute coordinates are being displayed.

6.2.2.4 Scale
Scale factors for any axes can be set by G51 and can be cleared by G50. If a scale factor
(other than 1.0) is set then it is applied to coordinates when they appear in G-code (e.g. as X
words, Y words etc.) . The Scale LED will flash as a reminder that a scale is set for an axis.
The value defined by G51 will appear, and can be set, in the Scale DRO. Negative values
mirror the coordinates about the relevant axis.

6.2.2.5 Softlimits
The Softlimits button enables the softlimits values defined in Config>Homing/Limits.

6.2.2.6 Verify
The Verify button, which is only applicable if you have home switches, will move to them
to verify if any steps might have been lost during preceding machining operations.

6.2.2.7 Diameter/Radius correction

Rotary axes can have the approximate size of the workpiece defined using the Rotational
Diameter control family. This size is used when making blended feedrate calculations for
co-ordinated motion including rotational axes. The LED indicates that a non-zero value is
defined.

6.2.3 "Move to" controls

There are many buttons on different screens designed to
make it easy to move the tool (controlled point) to a
particular location (e.g. for a tool change). These
buttons include: Goto Zs to move all axes to zero, Goto
Tool Change, Goto Safe Z, Goto Home.
In addition Mach3 will remember two different sets of
coordinates and go to them on demand. These are
controlled by Set Reference Point and Goto Ref Point,
and by Set Variable Position and Goto Variable
Position
Figure 6.4 – Controlled point
memories & Teach
6.2.4 MDI and Teach control family
G-code lines
(blocks) can be
entered, for
immediate
execution, into the
MDI (Manual Data
Input) line. This is
selected by
clicking in it or the Figure 6.5 – MDI line
Rev 1.84-A2 6-3 Using Mach3Mill
 Mach3 controls and running a part program

MDI hotkey (Enter in the default configuration). When

the MDI line is active its color changes and a flyout box
showing the recently entered commands is displayed.
An example is shown in figure 6.5. The cursor up and
down arrow keys can be used to select from the flyout
so that you can reuse a line that you have already
entered. The Enter key causes Mach3 to execute the
current MDI line and it remains active for input of
another set of commands. The Esc key clears the line
and de-selects it. You need to remember that when it is
selected all keyboard input (and input from a keyboard
emulator or custom keyboard) is written in the MDI line
rather than controlling Mach3. In particular, jogging
keys will not be recognised: you must Esc after entering
MDI.
Mach3 can remember all the MDI lines as it executes
them and store them in a file by using the Teach
facility. Click Start Teach, enter the required commands
and then click Stop Teach. The LED blinks to remind
you that you are in Teach Mode. The commands are
written in the file with the conventional name
"C:/Mach3/GCode/MDITeach.tap" Clicking Load/Edit
will load this file into Mach3 where it can be run or
edited in the usual way – you need to go to the Program
Run screen to see it. If you wish to keep a given set of
taught commands then you should Edit the file and use
Save As in the editor to give it your own name and put it
in a convenient folder.

6.2.5 Jogging control family

Jogging controls are collected on a special screen which Figure 6.6 - Jogging control
flys-out into use when the Tab key is pressed on the family
keyboard. It is hidden by a second press of Tab.
This is illustrated in figure 6.6/
Whenever the Jog ON?OFF button is displayed on the current screen then the axes of the
machine can be jogged using (a) the jog hotkeys – including an MPG connected via a
keyboard emulator: the hotkeys are defined in Configure Axis hotkeys; (b) MPG handwheel
(s) connected to an encoder on the parallel port; or a Modbus device (c) joysticks interfaced
as USB Human Interface Devices; or (e) as a legacy feature, a Windows compatible analog
joystick.
If the Jog ON/OFF button is not displayed or it is toggled to OFF then jogging is not
allowed for safety reasons.

6.2.5.1 Hotkey jogging

There are three modes. Continuous, Step and MPG which are selected by the Jog Mode
button and indicated by the LEDs.
Continuous mode moves the axis or axes at the defined slow jog rate while the hotkeys are
depressed
The jogging speed used with hotkeys in Continuous mode is set as a percentage of the rapid
traverse rate by the Slow Jog Percentage DRO. This can be set (in the range 0.1% to 100%)
by typing into the DRO. It can be nudged in 5% increments by the buttons or their hotkeys.
This Slow Jog Percentage can be overridden by depressing Shift with the hotkey(s). An
LED beside the Cont. LED indicates this full speed jogging is selected
Step mode moves the axis by one increment (as defined by the Jog Increment DRO) for
each keypress. The current feedrate (as defined by the F word) is used for these moves.
Using Mach3Mill 6-4 Rev 1.84-A2
 Mach3 controls and running a part program

The size of increment can be set by typing it into the Step DRO or values can be set in this
DRO by cycling through a set of 10 user definable values using the Cycle Jog Step button.
Incremental mode is selected by the toggle button or, if in Continuous Mode temporarily
selected by holding down Ctrl before performing the jog.

6.2.5.2 Parallel port or Modbus MPG jogging

Up to three quadrature encoders connected to the parallel ports or ModBus can be
configured as MPGs for jogging by using the Jog Mode button to select MPG Jog Mode.
The axis that the MPG will jogs is indicated by the LEDs and the installed axes are cycled
through by the Alt-A button for MPG1, Alt-B for MPG2 and Alt-C for MPG3.
Over the graphic of the MPG handle are a set of buttons for selecting the MPG mode.
In MPG Velocity Mode the velocity of the axis movement is related to the rotational speed
of the MPG with Mach3 ensuring that the acceleration of the axis and top speed if
honoured. This gives a very natural feel to axis movement. MPG Step/Velocity mode
currently works like velocity mode.
In Single Step mode each "click" from the MPG encoder requests one incremental jog step
(with the distance set as for hotkey Step jogging). Only one request at a time will be
allowed. In other words if the axis is already moving then a “click” will be ignored. In
Multi-step mode, clicks will be counted and queued for action. Note that this means that for
large steps rapid movement of the wheel may mean that the axis moves a considerable
distance and for some time after the wheel movement has stopped. The steps are
implemented with the federate given by
the MPG Feedrate DRO
These step modes are of particular use in
making very fine controlled movements
when setting up work on a machine. You
are advised to start using Velocity Mode.

6.2.5.3 Spindle Speed control family

Depending on the design of your
machine, the machine spindle can be
controlled in three ways: (a) Speed is
fixed/set by hand, switched on and off by
hand; (b) Speed fixed/set by hand,
switched on and off by M-codes via
external activation outputs, (c) Speed set Figure 6.6 - Spindle speed control family
by Mach3 using PWM or step/direction
drive.
This control family is only important for case (c).
The S DRO has its value set when an S word is used in a part program. It is the desired
spindle speed. It can also be set by typing into the DRO.
Mach3 will not allow you to try to set it (in either way) to a speed less than that set in Min
Speed or greater than that set in Max Speed on Config>Port & Pins Spindle Setup tab for
the chosen pulley.
If the Index input is configured and a sensor which generates pulses as the spindle revolves
is connected to its pin, then the current speed will be displayed in the RPM DRO. The RPM
DRO cannot be set by you – use the S DRO to command a speed..

6.2.6 Feed control family

6.2.6.1 Feed Units per minute

The Prog Feed DRO gives the feed rate in current units (inches/millimetres per minute). It
is set by the F word in a part program or by typing into the F DRO. Mach3 will aim to use
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 Mach3 controls and running a part program

this speed as the actual rate of the co-ordinated

movement of the tool through the material. If
this rate is not possible because of the
maximum permitted speed of any axis then the
actual feed rate will be the highest achievable.

6.2.6.2 Feed Units per rev.

As modern cutters are often specified by the
permitted cut per "tip" it may be convenient to
specify the feed per revolution (i.e. feed per tip
x number of tips on tool). The Prog Feed DRO
gives the feed rate in current units
(inches/millimetres) per rev of the spindle. It is
Figure 6.7 Feed control family
set by the F word in a part program or by typing
into the DRO.
A revolution of the spindle can either be determined by the S DRO or from the measured
speed by counting index pulses. Config>Logic has a checkbox to define which Mach3 will
adopt.
To employ Feed units/rev, Mach3 must know the value of the chosen measure of the speed
of the spindle (i.e. it must have been (a) defined in an S word or by data entered to S DRO
in the Spindle speed control family or (b) the Index must be connected up to measure actual
spindle speed).
Notice that the numeric values in the control will be very different unless spindle speed
is near to 1 rpm! So using a feed per minute figure with feed per rev mode will
probably produce a disastrous crash.

6.2.6.3 Feed display

The actual feed in operation allowing for the co-ordinated motion of all axes is displayed in
Units/min and Units/rev. If the spindle speed is not set and the actual spindle speed is not
measured then the Feed per rev value will be meaningless.

6.2.6.4 Feed override

Unless M49 (Disable feedrate override) is in use, the feedrate can be manually overridden,
in the range 20% to 299%, by entering a percentage in the DRO. This value can be nudged
(in steps of 10%) with the buttons or their keyboard shortcuts and be reset to 100%. The
LED warns of an override is in operation.
The FRO DRO displays the calculated result of applying the percentage override to the set
feedrate.

6.2.7 Program Running control family

These controls handle the execution of a loaded part program or the commands on an MDI
line.

6.2.7.1 Cycle Start

Safety warning: Note that the Cycle Start button will, in general, start the spindle and axis
movement. It should always be configured to require "two hand" operation and if you are
assigning your own hotkeys it should not be a single keystroke.

6.2.7.2 FeedHold
The Feedhold button will stop the execution of the part program as quickly as possible but
in a controlled way so it can be restarted by Cycle Start. The spindle and coolant will
remain on but can be stopped manually if required.
When in FeedHold you can jog the axes, replace a broken tool etc. If you have stopped the
spindle or coolant then you will generally want to turn them on before continuing. Mach3
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 Mach3 controls and running a part program

will however, remember the axis positions at the time of the FeedHold and return to them
before continuing the part program

Figure 6.8 - Program running family

6.2.7.3 Stop
Stop halts axis motion as quickly as possible. It may result in lost steps (especially on
stepper motor driven axes) and restarting may not be valid.

6.2.7.4 Rewind
Rewinds the currently loaded part program.

6.2.7.5 Single BLK

SingleBLK is a toggle (with indicator LED). In Single Block mode a Cycle Start will
execute the next single line of the part program and then enter FeedHold.

6.2.7.6 Reverse Run

Reverse Run is a toggle (with indicator LED). It should be used after a Feed Hold or Single
Block and the next Cycle Start will cause the part program to run in reverse. This is
particularly useful in recovering from a lost arc condition in plasma cutting or a broken tool.

6.2.7.7 Line Number

Line DRO is the ordinal number of the current line in the G-code display window (starting
from 0). Note that this is not related to the "N word" line number.
You can type into this DRO to set the current line.

6.2.7.8 Run from here

Run from here performs a dummy run of the part program to establish what the modal state
(G20/G21, G90/G91 etc.) should be and then prompts for a move to put the controlled point
in the correct position to for the start of the line in Line Number. You should not attempt to
Run from here in the middle of a subroutine.

6.2.7.9 Set next line

Like Run from here but without the preparatory mode setting or move.

6.2.7.10 Block Delete

The Delete button toggles the Block Delete "switch". If enabled then lines of G-code which
start with a slash - i.e. / - will not be executed.

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 Mach3 controls and running a part program

6.2.7.11 Optional Stop

The End button toggles the Optional Stop "switch". If enabled then the M01 command will
be treated as M00.

6.2.8 File control family

These controls, figure 6.9, are involved with the file of your part program. They should be
self-evident in operation.

6.2.9 Tool details

In the Tool Details group, figure 6.9, controls display
the current tool, the offsets for its length and diameter
and, on systems with a Digities input, allow it to be
automatically zero to the Z plane.
Unless tool change requests are being ignored
(Config>Logic), on encountering an M6 Mach3 will
move to Safe Z and stop, flashing the Tool Change
LED. You continue (after changing the tool) by clicking
Cycle Start.
The elapsed time for the current job is displayed in
hours, minutes and seconds.

Figure 6.9 – Tool Details

6.2.10 G-Code and Toolpath control
family
The currently loaded part program is displayed in the G-code window. The current line is
highlighted and can be moved using the scroll bar on the window.
The Toolpath display, figure 6.10, shows the path that the controlled point will follow in the
X, Y, Z planes. When a part program is executing the path is overpainted in the color
selected in Config>Toolpath. This overpainting is dynamic and is not preserved when you
change screens or indeed alter views of the toolpath.
On occasions you will find that the display does not exactly follow the planned path. It
occurs for the following reason. Mach3 prioritises the tasks it is doing. Sending accurate
step pulses to the machine tool is the first priority. Drawing the tool path is a lower priority.
Mach3 will draw points on the toolpath display whenever it has spare time and it joins these
points by straight lines. So, if time is short, only a few points will be drawn and circles will

Figure 6.10 - Toolpath family

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 Mach3 controls and running a part program

tend to appear as polygons where the straight sides are very noticeable. This is nothing to
worry about.
The Simulate Program Run button will execute the G-code, but without any tool movement,
and allow the time to make the part to be estimated.
The Program Limits data allow you to check the maximum excursion of the controlled
point to be reasonable (e.g. not milling the top off the table).
The screenshot also shows axis DROs and some Program Run controls.
If you have defined softlimits which correspond to the size of your machine table then it is
often useful to use the Display Mode button to toggle from Job to Table mode to show the
toolpath in relation to the table. See figure 6.11
The toolpath display can be
rotated by left clicking and
dragging the mouse in it. It
can be zoomed by shift-left
clicking and dragging and
can be panned by dragging
a right click.
The Regenerate button will
regenerate the toolpath
display from the G-code
with the currently enabled
fixture and G92 offsets.
Note: It is very important
to regenerate the toolpath Figure 6.11 – Toolpath in relation to table
after changing the values of offsets both to get the correct visual effect and because it is
used to perform calculations when using G42 and G43 for cutter compensation..

6.2.11 Work offset and tool table control family

Work Offset and Tool tables can be accessed from the Operator menu and, of course, within
a part program but it is often most convenient to manipulate them through this family. Refer
to chapter 7 for details of the tables and techniques like "Touching".
Because of the underlying G-code definitions Work Offset and Tool tables work in slightly
different ways.
Warning: Changing the Work and Tool offsets in use will never actually move the tool on
the machine although it will of course alter the axis DRO readings. However, a move G0,
G1 etc.) after setting
new offsets will be in the
new coordinate system.
You must understand
what you are doing if you
wish to avoid crashes on
your machine.

6.2.11.1 Work Offsets

Mach3 by default uses
Work Offset number 1.
Choosing any value from
1 to 255, and entering it
in the Current Work
Offset DRO, will make
that Work Offset current.
Work offsets are
sometimes called Fixture Figure 6.12 – Work offsets family
Offsets.

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 Mach3 controls and running a part program

Typing into the DRO is equivalent to a part program issuing G55 to 59 or G58.1 to G59.253
(q.v.).
You can also set the current offset system using the Fixture buttons.
You can change the value of the offset values for the current offset system by typing into
the relevant Part Offset DROs. (Part Offset is yet another name for Work and Fixture
offsets!)
Values can also be set in these DROs by moving the axes to a desired place and clicking as
Set or Select button. The X and Y axes and Z axis are set in slightly different ways. Z is
easier to understand so we will describe it first.
The Z offset will usually be set up with a “master tool” in the spindle. The Z for other tools
will then be corrected by the tool table. A gage block or sometimes even a piece of foil or
paper is slid between the tool and the top of the work (if this is to be Z = 0.0) or the table (if
this is to be Z = 0.0). The Z axis is very gently jogged down until the gage is just trapped by
the tool. The thickness of the gage is entered into the Gage Block Height DRO and the Set Z
button is clicked. This will set up the Z value of the current work offset so that the tool is at
the given height.
The process for X and Y is similar except the touching might be done on any of four sides
of the part and account has to be taken of the diameter of the tool (or probe) and the
thickness of any gage being used to give “feel” to the touching process.
For example to set the bottom edge of a piece of material to be Y = 0.0 with a tool of
diameter 0.5” and a 0.1” gage block, you would enter 0.7 in the Edge Finder Dia DRO (i.e.
the diameter of the tool plus twice the gage) and click the Select button that is ringed in
figure 6.12.
Depending on your configuration of Persistent Offsets and Offsets Save in Config>State the
new values will be remembered from one run of Mach3 to another.

6.2.11.2 Tools
Tools are numbered from 0 to 255.
The tool number is selected by the
T word in a part program or
entering the number in the T DRO.
Its offsets are only applied if they
are switched On by the Tool Offset
On/Off toggle button (or the
equivalent G43 and G49 in the part
program)
In Mach3Mill only the Z offset and
Diameter are used for tools. The
diameter can be entered in the DRO
Figure 6.13 – Tool Offset
and the Z-offset (i.e. compensation
for tool length) be entered directly or by Touching. The Set Tool Offset feature works
exactly as set Z with with Work Offsets.
Tool Offset data is made persistent between runs in the same way as Work Offset data.

6.2.11.3 Direct access to Offset Tables

The tables can be opened and edited directly
using the Save Work Offsets and Save Tool
Offsets buttons or the Operator>Fixtures (i.e.
Work Offsets) and Operator>Tooltable menus.

6.2.12 Rotational Diameter control

family
Figure 6.14 - Rotational diameters
As described in the Feedrate control family, it is
possible to define the approximate size of a
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 Mach3 controls and running a part program

rotated workpiece so the rotational axis speed can be correctly included in the blended
feedrate. The relevant diameters are entered in the DROs of this family.
The Axis control Family has warning LED(s) to indicated the setting of non-zero values
here.
Values are not required if rotary movement is not to be coordinated with linear axes. In this
case a suitable F word for degrees per minute or degrees per rev should be programmed.

6.2.13 Tangential control family

On a machine to cut vinyl or fabric it is very useful to
use a rotary axis to control the direction that the knife
points. It will cut best if tangential to the direction in
which the X and Y axes are moving at any time.
Mach3 will control the A axis like this for G1 moves.
Clearly the point of the knife should be as near to the
axis about which a turns and this axis must be parallel Figure 6.15 – Tangential control
to the Z axis of the machine. family
The feature is enabled by the Tangential Control
.button. In most applications there is a limit to the angle through which the knife can be
turned at a corner while it is in the material. This value is defined in Lift Angle. Any corner
where the change in angle required is greater than Lift Angle will cause the Z axis to rise by
the value in Lift Z, the knife will turn and then Z will drop so it re-enters the material in the
new direction.

6.2.14 Limits and miscellaneous

control family

6.2.14.1 Input Activation 4

Input activation signal 4 can be configured to
give a hard wired Single Step function
equivalent to the Single button in the Program
Running control family.

6.2.14.2 Override limits

Mach3 can use software to override limit
switches connected to its inputs. Figure 6.16 - Limits control family

This can be automatic i.e. the jogging performed immediately after a reset will not be
subject to limits until the axis is jogged off the
limit switches. The Toggle button and warning
LED for Auto Limit Override controls this.
As an alternative limits may be locked out
using the OverRide Limits toggle. Its use is
indicated by the LED.
Notice that these controls do not apply if limit
switches are wired to the drive electronics or to
activate EStop. In this case an external
electrical override switch will be needed to
disable the switch circuit while you jog off
them.

6.2.15 System Settings control

family
Note: The controls in this family are not Figure 6.17 – System Settings, Safe Z
in one place on the screens released with controls etc.

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 Mach3 controls and running a part program

Mach3. You will need to hunt for them on Program Run, Settings and Diagnostics
screens.

6.2.15.1 Units
This toggle implements the G20 and G21 codes to change the current measurement units.
You are strongly advised not to do this except in small fragments of part program on
account of the fact that Work Offset and Tool Offset tables are in one fixed set of units.

6.2.15.2 Safe Z
This family allows you to define the Z value which is clear of clamps and parts of the
workpiece. It will be used for homing and changing the tool.

6.2.15.3 CV Mode/Angular Limit

This LED is lit when the system is running in "Constant Velocity" mode. This will give
smoother and faster operation than "Exact stop" mode but may cause some rounding at
sharp corners depending on the speed of the axis drives. Even when the system is in CV
mode a corner with a change of direction more acute than the value given in the Angular
Limit DRO will be performed as if Exact Stop was selected. Full details of this are given
under Constant Velocity in chapter 10.

6.2.15.4 Offline
This toggle and warning
LED "disconnects" all the
output signals of Mach3.
This is intended for
machine setup and testing.
Its use during a part
program will cause you all
sorts of positioning Figure 6.18 - Encoder control family
problems.

6.2.16 Encoder control family

This family displays the values from the axis encoders and allows them to be transferred to
and from the main axis DROs
The Zero button will reset the corresponding encoder DRO to zero.
The To DRO button copies the value into the main axis DRO (i.e. applies this values as a
G92 offset).
The Load DRO button loads the encoder DRO from the corresponding main axis DRO.

6.2.17 Automatic Z control family

Mach3 has the
facility to set a lower
limit for moves in the
Z axis. See
Config>Logic dialog
for the static setting Figure 6.19 – Automatic Z control
of this Inhibit-Z
value.
There is also a control family which allows this Inhibit Z value to be set while preparing
and before running a G-code program. This is shown in figure 6.19.
Code the program, which might often be a DXF or HPGL import, so that it makes a single
cut or set of cuts at the finally desired Z depth (perhaps Z = -0.6 inch assuming top of
workpiece is Z = 0). The last command should be an M30 (Rewind)

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 Mach3 controls and running a part program

Using the Automatic Z Control controls (a) set the Z-inhibit value to the Z for depth for the
first roughing cut (perhaps Z= -0.05) (b) the Lower Z-Inhibit to the successive cut depths
(we might allow 0.1 as the tool has some side support). The whole job will need seven
passes to get to Z = -0.6, so (c) enter 7 in L (Loop). On pressing Cycle Start the machine
will automatically make the series of cuts at increasing Z depth. The DROs track the
progress decrementing L as they are performed and updating the Z-inhibit value. If the
given number of L does not reach the part program's requested Z depth then you can update
the L DRO and restart the program.

6.2.18 Laser Trigger output family

Mach3 will output a pulse on the Digitise Trigger Out Pin
(if defined) when the X or Y axes pass through trigger
points.
The Laser Trigger group of controls allows you to define
the grid points in the current units and relative to an
arbitrary datum.
Click Laser Grid Zero when the controlled point is at the
desired grid origin. Define the positions of the grid lines in
X and Y axes and click Toggle to enable the output of
pulses whenever an axis crosses a grid line. Figure 6.20 – Digitise Pulse
family
This feature is experimental and subject to change in later
releases.

6.2.19 Custom controls families

Mach3 allows a machine builder, which could be you or your supplier, to add a whole range
of features by custom screens which can have DROs, LEDs and buttons which are used by
VB Script programs (either attached to the buttons or run from macro files). Examples of
such facilities are given in the Mach3 Customisation manual. These example also show how
different Mach3 screens can look to suit different applications even though they perform
essentially the same function required by a milling machine or router.

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 Mach3 controls and running a part program

6.3 Using Wizards

Mach3 Wizards are
an extension to the
Teach facility which
allows you to define
some machining
operations using one
or more special
screens. The Wizard
will then generate G-
code to make the
required cuts.
Examples of Wizards
include machining a
circular pocket,
drilling an array of
holes and engraving
text. Figure 6.21 – Choosing a Wizard
The Load Wizards
button displays a table of Wizards installed on your system. You choose the one required
and click Run. The Wizard screen (or sometimes one of several screens) will be displayed.
Chapter 3 includes an example for milling a pocket. Figure 6.22 is the Wizard for engraving
text.

Figure 6.22 – The Write Wizard screen

Wizards have been contributed by several authors and depending on their purpose there are
slight differences in the control buttons. Each Wizard will however have a means of posting
the G-code to Mach3 (marked Write in figure 6.22) and a means of returning to the main
Mach3 screens. Most Wizards allow you to save your settings so that running the Wizard
again gives the same initial values for the DROs etc.

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 Mach3 controls and running a part program

Figure 6.23 shows a section of the Toolpath screen after the Write button is pressed on
figure 6.22.

Figure 6.23 – After running the Write wizard

The Last Wizard buttons runs the wizard you most recently used without the trouble of
selecting it from the list.
The Conversational button runs a set of wizards designed by Newfangled Solutions. These
are supplied with Mach3 but require a separate license for them to be used to generate code.

6.4 Loading a G-code part program

If you have an
existing part program
which was written by
hand or a CAD/CAM
package then you
load it into Mach3
using the Load G-
Code button. You
choose the file from
a standard Windows
file open dialog.
Alternatively you can
choose from a list of
recently used files
which is displayed
by the Recent Files
screen button. Figure 6.24 – Loading G-Code

When the file is chosen, Mach3 will load and analyse the code. This will generate a toolpath
for it, which will be displayed, and will establish the program extrema.
The loaded program code will be displayed in the G-code list window. You can scroll
through this moving the highlighted current line using the scroll bar.

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 Mach3 controls and running a part program

6.5 Editing a part program

Provided you have defined a program to be used as the G-code editor (in Config>Logic),
you can edit the code by clicking the Edit button. Your nominated editor will open in a new
window with the code loaded into it.
When you have finished editing you should save the file and exit the editor. This is
probably most easily done by using the close box and replying Yes to the "Do you want to
save the changes?" dialog.
While editing, Mach3 is suspended. If you click in its window it will appear to be locked
up. You can easily recover by returning to the editor and closing it.
After editing the revised code will again be analysed and used to regenerate the toolpath
and extrema. You can regenerate the toolpath at any time using the Regenerate button.

6.6 Manual preparation and running a part program

6.6.1 Inputting a hand-written program

If you want to write a program "from scratch" then you can either do so by running the
editor outside Mach3 and saving the file or you can use the Edit button with no part
program loaded. In this case you will have to Save As the completed file and exit the editor.
In both cases you will have to use File>Load G-code to load your new program into Mach3.
Warning: Errors in lines of code are generally ignored. You should not rely on being given
a detailed syntax check.

6.6.2 Before you run a part program

It is good practice for a part program to make no assumptions about the state of the machine
when it starts. It should therefore include G17/G18/G19, G20/G21, G40, G49, G61/G62,
G90/G91, G93/G94.
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You should ensure that the axes are in a known reference position - probably by using the
Ref All button.
You need to decide whether the program starts with an S word or if you need to set the
spindle speed by hand or by entering a value in the S DRO.
You will need to ensure that a suitable feedrate is set before any G01/G02/G03 commands
are executed. This may be done by an F word or entering data into the F DRO.
Next you may need to select a Tool and/or Work Offset.
Finally, unless the program has been proved to be valid you should attempt a dry run,
cutting "air" to see that nothing terrible happens.

6.6.3 Running your program

You should monitor the first run of any program with great care. You may find that you
need to override the feed rate or, perhaps, spindle speed to minimise chattering or to
optimise production. When you want to make changes you should either do this on the "fly"
or use the Pause button, make your changes and the click Cycle Start.

6.7 Building G-code by importing other files

Mach3 will convert files in DXF, HPGL or JPEG
format into G-code which will cut a representation
of them.
This is done using the File>Import
HPGL/BMP/JPG or the File>Import>DXF menu.
Having chosen a file type you have to load the
original file. You are prompted for parameters to
define the conversion and feed and coolant Figure 6.27 Choosing import filter
commands to be included in the part program. You
the import the data. Mach3 has to create a .TAP working file which contains the generated
G-code, so you will be prompted by a file save dialog for a name and folder for this.
The .TAP file is then loaded into Mach3 and you can run it as with any other part program.
Full details of the conversion processes and their parameters are given in chapter 8.

Rev 1.84-A2 6-17 Using Mach3Mill