Note that this section only specifies how to setup the machine (e.g. calibration, spindle setup and etc). To align reference between the machine space and 3D-model space please follow our separate How to Run the Machine section. To ensure the appropriate maintenance of the machine, we advise going through a number of steps. This machine is a desktop-type unit, install it in a location that allows an easy access to areas such as the power switch during operation. Adjust the profiles/fixtures, sensor target plates, measure the tool in the spindle. The fixtures should be placed in a position according to the dimensions of your stock. Before calibrating and providing a Homing Script check sensors, jog each axis to the sensor and check if those are activated once reach sensor plates.

Axis Directions and Coordinates System

 

 

Calibration and Homing Script

Prior to running 5XM machine, you must produce B and C axis Homing Script. BC Homing Script is a G-code script that sets B and C axis to machine’s true zero position. This should be followed by a wide range of reasons: Prevent the misalignment between the stock and the toolpath. Ensure of the safe operation of 5axismaker. Avoid the repetitive calibration and adjustment between the machine and the software. To produce a Homing Script you’ll go through step-by-step set of instructions: Calibrate C-axis and save C value, Calibrate B-axis and save B value, copy and save C and B axis values in a form of a code (e.g. BC Homing Script) that you need to run every time you switch on the machine.

Calibration Overview

Note: The following 3 calibration steps are compulsory and need to be completed following the order, while we can select one option or the other for Set-to-Zero routine (i.e. either go for Option 1, otherwise Option 2).

Step 1. Calibrate C-axis and save C-value

Step 2. Calibrate B-axis and save B-value

Step 3. Create a BC Homing Script

Set-to-Zero Routine Overview (i.e How to Run the Machine section)

Option 1 Set-to-Zero to Stock

Option 2 Set-to-Zero to Sensors and offset to stock

 

Tip: Use a Dial Test Indicator (i.e. DTI) for our B and C calibration.

C-axis Calibration: 

Step 1. Start at a random position

Switch on and connect 5axismaker to Mach3.

Step 2. Bring axis to the sensor and set to 0

In Mach3, in the MDI Alt2 section above type the following command in the Input window: The code to bring axis to its sensors: G28.1 C0 “Enter” G92 C0 “Enter”

G28.1 C0 - brings C to C sensor target
G92 C0 - sets current position as zero point

Step 3. Adjust axis to Dial Test Indicator (i.e. DTI ) and make sure to have the least amount of deviation on the DTI

Use a Dial Test Indicator placed against the front face of C-axis to test parallelism of C-axis to Y-axis. By jogging machine in Y-axis move the surface of the head against DTI and adjust C-axis angle (jog C-axis) until DTI doesn’t show any deviation. Go to Mach3 and write down C-axis value (e.g. 20.679) also note this number for the homing script - this will be our CXXX value in the homing script. Measure this accurately to ensure the machine is set precisely. This will save time in the long term.

B-axis Calibration:

Repeat similar steps for B-axis.

Step 1. Start at a random position

Switch on and connect 5axismaker to Mach3.

Step 2. Bring axis to the sensor and set to 0

In Mach3, in the MDI Alt2 section above type the following command in the Input window: The code to bring axis to its sensors:
G28.1 B0 - brings B target to B sensor
G92 B0 - sets current position as zero point

Step 3. Adjust axis to Dial Test Indicator (i.e. DTI ) and make sure to have the least amount of deviation on the DTI

Use a Dial Test Indicator placed against the front face of C-axis to test parallelism of C-axis to Y-axis. By jogging machine in Y-axis move the surface of the head against Dial Test Indicator and adjust B-axis angle (jog B-axis) until DTI doesn’t show any deviation. Go to Mach3 and write down B-axis value (e.g. -43.133) also note this number for the homing script - this will be our BXXX value in the homing script. Measure this accurately to ensure the machine is set precisely. This will save time in the long term.

BC Homing Script

Once B and C axis are calibrated, values are written down we can save the BC Homing Script as a text file. Create a Homing Script once and run it every time you switch on the machine. An example from the case study:

G92 C0 B0

G28.1 C0
G92 C0
G0 Cxxx (offset to perpendicular position)
G92 C0
G28.1 B0
G92 B0
G0 Bxxx
G92 B0

This would be your Homing Script File that you can run each time you’re operating 5axismaker. Run this code in Mach3 to bring BC axis to its calibrated position.

Note: It is recommended to have two sets of calibration for B and C axis - cold and hot, cold calibration is used when you home the machine right at the beginning (i.e. our first calibration values). Hot calibration can be recorded in the middle of work, in other words, rehome the machine in order to verify any potential deviations with our previous values.

 

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Spindle Setup

Spindle Collet Assembly: follow the steps accordingly.

Insert the nut into the collet, make sure that it clicks and locks in place. Insert milling tool into the collet, then check that the shank goes all the way through the collet. Ensure that the milling bit shank is not touching the back of the spindle taper before tightening. 

Hold the motor and tighten collet with a wrench firmly. Identify spindle direction according to your tool direction. We advise running spindle at its maximum speed at 15000RPM for maximum torque.

Note: Every tool has an indexical lip, each time tool is changed it is indexed back to its position, this feature has been designed instead of having an expensive automatic tool changer and allows to have a few milling heads with pre-set bits and swap those around without any additional setup.

Inserting the Tool: follow the steps and review the video below if necessary.

Untighten the M4 bolt with a hex key, wedge a steel ruler in the bracket horizontally and insert the tool into the bracket. Push the tool all the way through and tighten the bolt.  Connect 3 cables in any order. If you later need to change the direction of the spindle swap any two cables.

 

Tip: Quick Tool Change We recommend having two spindles, one for the roughing strategy, for example (6mm or equivalent, Square End) and one for finishing strategy (4mm or equivalent, Ball End).

 

Tool Measurement

Measure each tool with high precision. The diagram below illustrates Tool Length 1 is what we consider for Fusion360, HSM, MasterCAM, SolidCAM, and Powermill. Tool Length 2 is for 5xMonkey.

Option 1: Dial Test Indicator, DTI (Recommended)

We recommend using DTI for measuring the tool length as it seems to be the most convenient method in terms of the availability of measuring instruments and accuracy.

Note: Ensure on the perpendicularity of our B and C axis prior to the measurement of the tool by bringing them to zero.

Prepare the spindle with the preselected tool, install it on the machine head. Pick a Dial Test Indicator that will be used for the calibration process at a later stage and secure it to the machine frame. Jog the machine towards the bottom of the spindle and make sure that it doesn’t collide with the dial.

Generally, tool length is measured from the bottom of spindle to end of a tool tip with DTI applied exactly the same pressure on both ends. Touch face of the spindle with DTI tip, depress the dial tip so that the spin indicator “clock” hand small and large. Apply pressure on dial indicator for large “clock” hand to be at 30-50 units.

Then, set the Z-axis to zero in Mach3 and the dial itself.

Position tip of the tool over the DTI tip. Slowly jog the tip of the tool down, move until the DTI shows the same number as on the readings above - 30-50 units and take Z-axis readings on Mach3.

It is important to measure from the lowest point of the tool. To help you find the lowest point on the tool, adjust slowly the whole spindle counter-clockwise to avoid damaging the tool or the dial.

 

In Mach3, we can see the value of Z-axis went up by 52.765 - this would be your total length of the tool.

Note: In case of using the dial for the tool measurement, please skip the next two options.

Option 2: Height Gauge

There are many ways of estimating the milling tool, thus height gauge or calliper can be used accordingly.

 

Option 3: Caliper

 

Note: Keep the same tool length as per file values, otherwise, input new value (i.e. the difference between the tool lengths) into the file to make sure tool lengths on the machine and in digital space are precisely the same. Recalculate G-code with the adjusted difference between the tools. Formula: new tool - old tool = value that will go into the Z window e.g. -2.78 then G0 Z-2.78, set Z to zero, now we have another zero position for the difference in our tools.

Spindle Direction

Check on the direction of the spindle prior to the milling stage. Certain end mills may run strictly in the rotation appropriate for their classification. Turn on the spindle at the most preferred speed rate by typing the command in the Input window in Mach3:

M03 Sxx : where M03 means spindle rotation S is referred to as a percentage rate at a certain number of turns per minute, RPM. For example, to run the spindle at 30% speed rate of full 100% 15,000RPM would be: M03 S30 

To change the direction of the tool, swap either two cables on the spindle.

Proceed to Working with the Machine section.