Acu-Rite Control System MILLPWRG2 User Manual

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7.1 Demonstration Program
Running the program
The first step in running a new program is to establish datum. 
Remember to chose the center of the bolt circle as datum.
Place the workpiece into a vise.
Place the first tool of the program into the spindle.
From the DRO screen, press the  Move Table soft key. Using the 
arrows, and soft keys, position the workpiece under the tool where 
the center of the bolt circle’s datum is to be.
After the table has been properly positioned, press the  Exit soft key  
to return to the DRO screen.
Touch the tool to the top surface of your workpiece.
Press the Datum soft key.
Press the X = 0, Y = 0 and Z = 0 soft keys to establish the current 
tool position as datum.
Press the DOWN ARROW key.
Set the Z retract position 1” above the workpiece.
Press the USE key. 
						

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7.1 Demonstration Program
Tool changes
Whenever you encounter a Set Tool step, MILLPWRG2 will display the 
DRO screen and let you know which tool to load. If no tool diameter 
was programmed in the Tool Step, a prompt will be displayed to 
provide one.
Use the Move Table soft key and ARROW keys to move the workpiece  
away from the tool.
Insert the required tool into the spindle.
Using the Move Table soft key, position the surface of a known 
depth on the workpiece under the tool.
Press the Datum soft key.
Position your tool so that it touches a known surface, then enter that 
position into the Z axis.
Press the USE key.
Raise the tool and press the GO key to continue the program.
Clearing the program
Press the DRO/PGM key to return to the Program mode.
Press the Clear Program soft key.
Press the Yes soft key to confirm exiting the program.
The program is cleared from the screen, and at any time another 
program can be loaded or a new program written. 
If a program is loaded, and saved, it does not have to be cleared to 
open a new program.
If for some reason a program can not be cleared with the 
Clear Program soft key, there is an alternate method.
Cycle the power to the console. While at the home (DRO 
mode) screen, prior to finding home, press and hold the 
CLEAR key for 5 seconds.
Follow the instructions to clear the current program.  
						

							Milling and Drilling 
						

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8.1 Milling and Drilling
8.1  Milling and Drilling
Overview
Most of the program steps described in this section can be performed 
as one-step milling functions from the DRO screen or be included as 
steps in a program. Many of the dialogues are similar in the way that 
the data is entered.  Much of the information in this chapter should be 
familiar after performing the demonstration program in Chapter 7.
Set Tool defines the tool and should appear as the first step in a 
program. A Set Tool step is required anywhere a tool change is 
required. MILLPWR
G2 will apply the latest tool setting to the program 
steps that follow. See Selecting a tool on page 137 as the following 
information is very similar.
For complete information regarding a 2 Axes system Refer to 
Chapter 1, Operating in 2 Axes and 3 Axes Modes on page 31.
Warning: Spindle speeds used in this manual are for 
example only. A spindle speed is totally dependant on 
many factors (i.e. material, if coolant is used, tool 
diameter, etc.). The speeds listed are not meant to be a 
recommendation.  
						

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8.1 Milling and Drilling
Selecting a tool
The first step for a program is to choose the tool that will be used to 
begin the machining. For this example, a 1/4” diameter Flat End Mill 
will be used as an example.
Press the DRO/PGM key to enter PGM mode.
Press the Program Steps soft key.
Press the Tool soft key to open the Set Tool dialogue.
In the Set Tool dialogue, the tool settings may be entered directly 
into the fields, the current settings from a tool in the Tool Table may 
be imported into the dialogue, or a tool in the table may be 
programmed by its number.
Entering the Tool data
In the Set Tool dialogue the cursor defaults to the Size: Diameter 
field. Enter 0.25 in the Size / Diameter field.
Select the unit of measure using the Inch or MM soft keys if a change 
is required.
ARROW DOWN to highlight the Tool Type field. The Length: field will be 
left blank.
Enter the plunge angle to be used when ramping into pockets.
If the tool can safely plunge straight down into the material, press 
the Plunge soft key or enter 90° for the angle.
ARROW DOWN to highlight the Tool Type field, press the Tool Types soft 
key to open the Tool Type drop down menu.
ARROW DOWN to highlight the Flat End Mill.
Press the ENTER key to select the tool.
Though in most cases, pressing the ENTER key will enter 
the data into the field, and place the cursor into the next 
field, the ARROW keys will be used in these steps for 
navigation, and entering data.
In most dialogues that contain a drop down menu, there 
are soft keys available for choosing a selection.  These 
examples will refer to the use of the soft keys when 
available. 
						

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8.1 Milling and Drilling
Importing Tool Settings from the Tool Table
Cursor to the Diameter field.
Press the Tool Table soft key to open the table.
Cursor to the tool to be used and press the USE key.  The tool’s 
diameter, length, plunge angle, and type are transfered to the Set 
Tool dialogue.
Specifying  the tool by its tool table number
Cursor to the Tool Number field.
If the tool’s number is known, enter the number (1-99), and press 
the ENTER key.
If the tool’s number is not known, press the Tool Table soft key to 
open the table.
Cursor to the tool to be used and press the USE key. The tool’s 
number is transfered to the Set Tool dialogue.
Entering spindle data
ARROW DOWN to highlight the Spindle: field.
Press the Forward soft key.
Entering speed data
ARROW DOWN to the Speed: field (RPM) and enter the speed required 
(e.g. 1300) using the numeric keypad.
When the tool is specified by number, only the tool 
number is saved to the program. The current tool settings 
for the specified tool are displayed in the dialogue, but not 
saved as part of the program step. The tool settings 
(diameter, length, plunge angle, and type) are retrieved 
from the tool table each time the SET TOOL step is run. 
						

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8.1 Milling and Drilling
Entering tool position
ARROW DOWN to tool position and enter the location where it is best to 
make a tool change away from the part and fixtures.
ARROW DOWN to the Required Change field and select Yes, or No.
Press the USE key.
The programming of a part can now begin.
MILLPWRG2 moves to the Tool Position before prompting 
the user for a tool change, making it unnecessary to 
program a Position Drill step before a tool change.
MILLPWRG2 prompts the user to change the tool if the 
Set Tool step has a different tool than the one currently 
mounted (as indicated in the status bar). If the Require 
Change field is set to Yes, then MILLPWR
G2 will always 
pause and prompt the user for a tool change (even if the 
Set Tool matches the currently mounted tool).
Tool length offsets are discussed on the following pages.
If the Tool Table is used to enter a tool, MILLPWRG2 will 
fill in the Diameter and Length fields in PGM mode only. 
						

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8.1 Milling and Drilling
Repeatable tool length offsets
Programming a tool
When a program is using the Tool Length function, there are two 
requirements that must be followed to ensure that the tip of all 
additional tools is actually where MILLPWR
G2 has calculated it to be.
All tools used must have a fixed, repeatable length.
The surface that the tool touches off on must be a repeatable 
surface and used for all tools added to the program.
This also applies to all tools added to the Tool Table.
Setting the Datum using an electronic edge finder is for illustration 
only, and is not a requirement.
Press the Datum soft key.
Touch the first tool to the top surface that will be used to set all other 
tools.
Press the Z = 0 soft key.
The Z axis Datum is now set to 0.00.
All tools entered into the tool table will have length offsets relative to 
the first tool Datum.    All tools entered after the first tool, whether into 
the tool table or into a program should have their length set using the 
Teach Tool Length soft key.
Once you have identified the tools you will be using, you can 
program the Tool Length Offsets into the Set Tool steps.
When all tools have been added to a program with their tool length 
offset programmed, MILLPWR
G2 will retain the offset information 
between each tool and the Datum.
If a program that is using tool offsets requires a change from where 
the initial first tool datum was set, MILLPWR
G2 will reset the offset 
information for the remaining tools.
When setting a the Datum, consideration of the height of the new 
location can avoid possible tool collision with the part when running 
the program. If necessary, reset the Z Retract height.
Tools and their offsets can be used from the Tool Table, and inserted 
into a program. The Datum for the program can be set at a new 
location as mentioned above. MILLPWR
G2 will reset the offset 
information for the remaining tools to the new location. Their offset 
will stay relevant to the new Datum.
After the tool information is established in the program, later you can 
edit the values as needed to adjust for accuracy and wear. 
						

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8.1 Milling and Drilling
Changing to a tool of unknown length in DRO mode
If you are in the DRO mode and need to set a new tool, do the following: 
Place the tool in the spindle.
From the DRO mode, press the TOOL key.
Enter the tool diameter, delete any data in the Length field.
Enter the necessary data in the remaining fields where applicable.
Press the GO key.
An Operator intervention message will appear asking you to “use” the 
selected tool.
Press the GO key to confirm that you have installed the tool.
At this point, your program’s tool length offsets are not valid. Follow 
the steps below to reestablish the Z axis datum and tool length offsets 
for your program.
Position the tool over the surface where the Datum was established 
for the other tools.
Touch the tip of the tool to the top surface.
Press the Teach Tool Length soft key.
 MILLPWR
G2 will now add this tool to the known tool offsets, and the 
program’s tool length offsets are now valid.
This tool length offset is only valid while the tool is mounted.  Once 
this tool is removed, these steps must be repeated to re-establish the 
tool length when it is used again. 
						

							1608 Milling and Drilling
8.1 Milling and Drilling
Changing to a tool of unknown length in a program
When running a program, it is possible to switch between tools of 
known length, to using a tool that has a non-repeatable length.
When the tool which has a non-repeatable length is mounted, it’s 
length will be established in the same manner as  above in DRO mode.
Place the tool in the spindle.
In the Set Tool dialogue, enter the necessary data in the  fields 
where applicable,  but delete any data in the Length field.
Press the USE key.
At this point, your program’s tool length offsets are no longer valid. 
perform the following steps to reestablish the Z axis datum and tool 
length offsets for the program.
Position the tool over the surface where the Datum was established 
for the other tools.
Touch the tip of the tool to the top surface.
Press the Teach Tool Length soft key.
MILLPWR
G2 will now add this tool to the known tool offsets, and the 
program’s tool length offsets are now valid.
This tool length offset is only valid while the tool is mounted.  Once 
this tool is removed, these steps must be repeated re-establish the 
tool length when it is used again.
By resetting Datum during a tool step within the program, all of the 
tool offsets in the program become valid again.