Mach3Mill_1.84.pdf

A user's guide to installation,

configuration and operation

Using Mach3Mill

The nurture, care and feeding of the Mach3

controlled CNC Mill

All queries, comments and suggestions welcomed via support@artofcnc.ca

Mach Developers Network (MachDN) is currently hosted at:

http://www.machsupport.com

Front cover: A vertical mill circa 1914

Back cover (if present): The old, gear, way of co-ordinating motion on mill table and a

rotary axis

This version is for Mach3Mill Release 1.84

Contents

Preface.............................................................................................1-1

Introducing CNC machining systems............................................2-1

2.1

Parts of a machining system...........................................................................................2-1

2.2

How Mach3 fits in...........................................................................................................2-2

An overview of Mach3 Machine Controller software...................3-1

3.1

Installation......................................................................................................................3-1

3.1.1

Downloading....................................................................................................................3-1

3.1.2

Installing...........................................................................................................................3-1

3.1.3

The vital re-boot...............................................................................................................3-2

3.1.4

Convenient desktop icons..................................................................................................3-2

3.1.5

Testing the installation......................................................................................................3-3

3.1.6

Driver Test after a Mach3 crash.........................................................................................3-4

3.1.7

Notes for manual driver installation and un-installation......................................................3-4

3.2

Screens............................................................................................................................3-4

3.2.1

Types of object on screens................................................................................................3-5

3.2.2

Using buttons and shortcuts...............................................................................................3-5

3.2.3

Data entry to DRO............................................................................................................3-6

3.3

Jogging............................................................................................................................3-6

3.4

Manual Data Input (MDI) and teaching.........................................................................3-7

3.4.1

MDI.................................................................................................................................3-7

3.4.2

Teaching...........................................................................................................................3-7

3.5

Wizards – CAM without a dedicated CAM software.....................................................3-8

3.6

Running a G-code program..........................................................................................3-10

3.7

Toolpath display............................................................................................................3-11

3.7.1

Viewing the toolpath.......................................................................................................3-11

3.7.2

Panning and Zooming the toolpath display......................................................................3-11

3.8

Other screen features....................................................................................................3-11

Hardware issues and connecting the machine tool.....................4-1

4.1

Safety - emphasised.........................................................................................................4-1

4.2

What Mach3 can control.................................................................................................4-1

4.3

The EStop control...........................................................................................................4-2

4.4

The PC parallel port.......................................................................................................4-3

4.4.1

The parallel port and its history.........................................................................................4-3

4.4.2

Logic signals.....................................................................................................................4-3

4.4.3

Electrical noise and expensive smoke................................................................................4-4

4.5

Axis drive options............................................................................................................4-5

4.5.1

Steppers and Servos..........................................................................................................4-5

4.5.2

Doing Axis drive calculations...........................................................................................4-6

4.5.3

How the Step and Dir signals work....................................................................................4-7

4.6

Limit and Home switches................................................................................................4-8

4.6.1

Strategies..........................................................................................................................4-8

4.6.2

The switches.....................................................................................................................4-8

4.6.3

Where to mount the switches.............................................................................................4-9

4.6.4

How Mach3 uses shared switches....................................................................................4-10

4.6.5

Referencing in action......................................................................................................4-10

Using Mach3Mill

Rev 1.84-A 2

Contents

4.6.6

Other Home and Limit options and hints.........................................................................4-11

4.7

Spindle control..............................................................................................................4-11

4.8

Coolant..........................................................................................................................4-13

4.9

Knife direction control..................................................................................................4-13

4.10

Digitise probe................................................................................................................4-13

4.11

Linear (glass scale) encoders.........................................................................................4-13

4.12

Spindle index pulse.......................................................................................................4-14

4.13

Charge pump - a pulse monitor....................................................................................4-15

4.14

Other functions.............................................................................................................4-15

Configuring Mach3 for your machine and drives.........................5-1

5.1 A configuration strategy.................................................................................................5-1

5.2 Initial configuration........................................................................................................5-1

5.2.1 Defining addresses of port(s) to use...................................................................................5-1

5.2.2 Defining engine frequency................................................................................................5-2

5.2.3 Defining special features...................................................................................................5-2

5.3 Defining input and output signals that you will use.......................................................5-2

5.3.1 Axis and Spindle output signals to be used........................................................................5-2

5.3.2 Input signals to be used.....................................................................................................5-3

5.3.3 Emulated input signals......................................................................................................5-4

5.3.4 Output Signals..................................................................................................................5-5

5.3.5 Defining encoder inputs....................................................................................................5-5

5.3.5.1 Encoders................................................................................................................5-5

5.3.5.2 MPGs....................................................................................................................5-6

5.3.6 Configuring the spindle.....................................................................................................5-6

5.3.6.1 Coolant control......................................................................................................5-6

5.3.6.2 Spindle relay control..............................................................................................5-6

5.3.6.3 Motor Control........................................................................................................5-6

5.3.6.4 Modbus spindle control..........................................................................................5-7

5.3.6.5 General Parameters................................................................................................5-7

5.3.6.6 Pulley ratios...........................................................................................................5-7

5.3.6.7 Special function.....................................................................................................5-7

5.3.7 Mill Options tab...............................................................................................................5-8

5.3.8 Testing.............................................................................................................................5-9

5.4 Defining the setup units..................................................................................................5-9

5.5 Tuning motors...............................................................................................................5-10

5.5.1 Calculating the steps per unit...........................................................................................5-10

5.5.1.1 Calculating mechanical drive................................................................................5-10

5.5.1.2 Calculating motor steps per revolution..................................................................5-11

5.5.1.3 Calculating Mach3 steps per motor revolution......................................................5-11

5.5.1.4 Mach3 steps per unit............................................................................................5-11

5.5.2 Setting the maximum motor speed...................................................................................5-12

5.5.2.1 Practical trials of motor speed...............................................................................5-12

5.5.2.2 Motor maximum speed calculations......................................................................5-13

5.5.2.3 Automatic setting of Steps per Unit......................................................................5-13

5.5.3 Deciding on acceleration.................................................................................................5-14

5.5.3.1 Inertia and forces..................................................................................................5-14

5.5.3.2 Testing different acceleration values.....................................................................5-14

5.5.3.3 Why you want to avoid a big servo error...............................................................5-14

5.5.3.4 Choosing an acceleration value.............................................................................5-14

5.5.4 Saving and testing axis....................................................................................................5-14

5.5.5 Repeat configuration of other axes..................................................................................5-15

5.5.6 Spindle motor setup........................................................................................................5-16

5.5.6.1

Motor speed, spindle speed and pulleys................................................................5-16

5.5.6.2

Pulse width modulated spindle controller..............................................................5-17

5.5.6.3

Step and Direction spindle controller....................................................................5-17

Rev 1.84-A 2

iii

Using Mach3Mill

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