An

Industry Oriented Mini Project report

On

“MILLING OPETARION USING COMPUTERIZED

NUMERICAL CONTROL”
In partial fulfilment of the requirement for the award degree of

BACHELOR OF TECHNOLOGY IN

MECHANICAL ENGINEERING

Submitted by
A ANIL KUMAR 165T1A0302
B VINOD 165T1A0303
CH MAHESH 165T1A0309
S SRIKANTH 165T1A0338

Under the guidance of

Mr. L. VIJAY, MTech. Assistant Professor

Department of Mechanical Engineering

DEPARTMENT OF MECHANICAL ENGINEERING

ASHOKA INSTITUTE OF ENGINEERING AND TECHNOLOGY

MALKAPUR (V), CHOUTAPPAL (M), YADADRI-BHONGIRI (D) – 508252

Approved by AICTE New Delhi, Recognized by Govt. of Telangana and

Affiliated to Jawaharlal Nehru Technological University, Hyderabad, Telangana.

2019-2020
 ASHOKA INSTITUTE OF ENGINEERING AND TECHNOLOGY
DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE

This is to certify that this is bonafide record as the Practical work done
by

A ANIL KUMAR 165T1A0302

B VINOD 165T1A0303
CH MAHESH 165T1A0309
S SRIKANTH 165T1A0338

submitted for the subject ME705PC Industry Oriented Mini Project as

IV Year I Semester of B. Tech during the academic Year 2019-20.

PROJECT GUIDE

Mr. L. VIJAY, MTech., EXTERNAL EXAMINER

(Assistant Professor/Mech)

HOD PRINCIPAL
Dr.A.RAMESH KUMAR Dr. M. SRIDHAR REDDY
 DECLARATION

We hereby declare that the work presented in the report entitled “MILLING

OPERATIONS USING COMPUTERIZED NUMAERICAL CONTROL”

by us for the subject Industry Oriented Mini Project of IV Year I Semester

B.Tech., in Mechanical Engineering have not submitted the matter embodied in

this report for the award of any degree or diploma.

A ANIL KUMAR 165T1A0302

B VINOD 165T1A0303
CH MAHESH 165T1A0309
S SRIKANTH 165T1A0338
 INDEX

Topic page No
CHAPTER 1: Introduction 06
CNC milling machine 06
1.1 overview CNC milling process 06
1.2 CNC milling operation 07
1.2.1 face milling 09
1.2.2 plane milling 09
1.2.3 angular milling 09
1.2.4 form milling 09
Chapter 2: other milling operations 10
2.1.1 stradle milling 10
2.1.2 gaug milling 10
2.1.3 pofile milling 10
2.1.4 gear milling 10
2.1.5 other machine process 10
2.2 CNC milling machine components 11
2.2.1 machine interface 11
2.2.2 column 11
2.2.3 knee 11
2.2.4 saddle 12
2.2.5 spindle 12
2.2.6 arbor 12
2.2.7 Ram 12
2.2.8 machine tools 12

2.3 milling machine considerations 12

2.4 types of milling machine 14
Chapter 3: material consideration 16
3.1 alternatives 16
Chapter 4: operations of milling machine 17
4.1 machine power ON 17
4.2 spindle warm up 17
4.3 device manger operation 18
4.4 file,display,column 19
Chapter 5: create new program 20
5.1 select the active program 20
5.2 check mark selection 20
Chapter 6: basic program search 25
6.1 tooling 25
6.2 tool holders 25
Chapter 7: CNC milling operations safty 26
7.1 do’s 28
7.2 dont’s 28
 CHAPTER-1
CNC Milling {Computer Numerical Control}

INTRODUCTION:
CNC milling, or computer numerical control milling, is a machining process which employs
computerized controls and rotating multi-point cutting tools to progressively remove material
from the workpiece and produce a custom-designed part or product. This process is suitable
for machining a wide range of materials, such as metal, plastic, glass, and wood, and producing
a variety of custom-designed parts and products.
Several capabilities are offered under the umbrella of precision CNC machining services,
including mechanical, chemical, electrical, and thermal processes. CNC milling is a mechanical
machining process along with drilling, turning, and a variety of other machining processes,
meaning that material is removed from the workpiece via mechanical means, such as the
actions of the milling machine’s cutting tools.
This article focuses on the CNC milling process, outlining the basics of the process, and the
components and tooling of the CNC milling machine. Additionally, this article explores the
various milling operations and provides alternatives to the CNC milling process.

1.1 Overview of CNC Milling Process

Like most conventional mechanical CNC machining processes, the CNC milling process
utilizes computerized controls to operate and manipulate machine tools which cut and shape
stock material. In addition, the process follows the same basic production stages which all CNC
machining processes do, including:

 Designing a CAD model

 Converting the CAD model into a CNC program
 Setting up the CNC milling machine
 Executing the milling operation

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The CNC milling process begins with the creation of a 2D or 3D CAD part design. Then the
completed design is exported to a CNC-compatible file format and converted by CAM software
into a CNC machine program which dictates the actions of the machine and the movements of
the tooling across the workpiece. Before the operator runs the CNC program, they prepare the
CNC milling machine by affixing the workpiece to the machine’s work surface (i.e., worktable)
or workholding device (e.g., vise), and attaching the milling tools to the machine spindle. The
CNC milling process employs horizontal or vertical CNC-enabled milling machines—
depending on the specifications and requirements of the milling application—and rotating
multi-point (i.e., multi-toothed) cutting tools, such as mills and drills. When the machine is
ready, the operator launches the program via the machine interface prompting the machine to
execute the milling operation.
Once the CNC milling process is initiated, the machine begins rotating the cutting tool at speeds
reaching up to thousands of RPM. Depending on the type of milling machine employed and
the requirements of the milling application, as the tool cuts into the workpiece, the machine
will perform one of the following actions to produce the necessary cuts on the workpiece:
1. Slowly feed the workpiece into the stationary, rotating tool
2. Move the tool across the stationary workpiece
3. Move both the tool and workpiece in relation to each other

As opposed to manual milling processes, in CNC milling, typically the machine feeds
moveable workpieces with the rotation of the cutting tool rather than against it. Milling
operations which abide by this convention are known as climb milling processes, while
contrary operations are known as conventional milling processes.

Generally, milling is best suited as a secondary or finishing process for an already machined
workpiece, providing definition to or producing the part’s features, such as holes, slots, and
threads. However, the process is also used to shape a stock piece of material from start to finish.
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In both cases, the milling process gradually removes material to form the desired shape and
form of the part. First, the tool cuts small pieces—i.e., chips—off the workpiece to form the
approximate shape and form. Then, the workpiece undergoes the milling process at much
higher accuracy and with greater precision to finish the part with its exact features and
specifications. Typically, a completed part requires several machining passes to achieve the
desired precision and tolerances. For more geometrically complex parts, multiple machine
setups may be required to complete the fabrication process.

Once the milling operation is completed, and the part is produced to the custom-designed
Specifications, the milled part passes to the finishing and post-processing stages of production.

1.2 CNC Milling Operations

Examples of tooling for milling machine operations, including cutters, drills, and
broaching bits.

CNC milling is a machining process suitable for producing high accuracy, high tolerance parts
in prototype, one-off, and small to medium production runs. While parts are typically produced
with tolerances ranging between +/- 0.001 in. to +/- 0.005 in., some milling machines can
achieve tolerances of up to and greater than +/- 0.0005 in. The versatility of the milling process
allows it to be used in a wide range of industries and for a variety of part features and design

including slots, chamfers, threads, and pockets. The most common CNC milling operations
include:

 Face milling
 Plain milling
 Angular milling
 Form milling
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1.2.1 Face Milling

Face milling refers to milling operations in which the cutting tool’s axis of rotation is
perpendicular to the surface of the workpiece. The process employs face milling cutters which
have teeth both on the periphery and tool face, with the peripheral teeth primarily being used
for cutting and the face teeth being used for finishing applications. Generally, face milling is
used to create flat surfaces and contours on the finished piece and is capable of producing
higher quality finishes than other milling processes. Both vertical and horizontal milling
machines support this process.

Types of face milling include end milling and side milling, which use end milling
cutters and side milling cutters, respectively.

1.2.2 Plain Milling

Plain milling, also known as surface or slab milling, refers to milling operations in which the
cutting tool’s axis of rotation is parallel to the surface of the workpiece. The process
employs plain milling cutters which have teeth on the periphery that perform the cutting
operation. Depending on the specifications of the milling application, such as the depth of the
cut and the size of the workpiece, both narrow and wide cutters are used. Narrow cutters allow
for deeper cuts, while wider cutters are used for cutting larger surface areas. If a plain milling
application requires the removal of a large amount of material from the workpiece, the operator
first employs a coarse-toothed cutter, slow cutting speeds, and fast feed rates to produce the
custom-designed part’s approximate geometry. Then, the operator introduces a finer toothed
cutter, faster cutting speeds, and slower feed rates to produce the details of the finished part.

1.2.3 Angular Milling

Angular milling, also known as angle milling, refers to milling operations in which the cutting
tool’s axis of rotation is at an angle relative to the surface of the workpiece. The process
employs single-angle milling cutters—angled based on the particular design being machined—
to produce angular features, such as chamfers, serrations, and grooves. One common
application of angular milling is the production of dovetails, which employs 45°, 50°, 55°, or
60° dovetail cutters based on the design of the dovetail.

1.2.4 Form Milling

Form milling refers to milling operations involving irregular surfaces, contours, and outlines,
such as parts with curved and flat surfaces, or completely curved surfaces. The process employs
formed milling cutters or fly cutters specialized for the particular application, such as convex,
concave, and corner rounding cutters. Some of the common applications of form milling
include producing hemispherical and semi-circular cavities, beads, and contours, as well as
intricate designs and complex parts with a single machine setup.

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 CHAPTER-2
Other Milling Machine Operations

Besides the aforementioned operations, milling machines can be used to accomplish other
specialized milling and machining operations. Examples of the other types of milling machine
operations available include:

2.1.1 Straddle milling: Straddle milling refers to milling operations in which the machine
tool machines two or more parallel workpiece surfaces with a single cut. This process employs
two cutters on the same machine Arbor, arranged such that the cutters are at either side of the
workpiece and can mill both sides at the same time.

2.1.2 Gang milling: What is gang milling? Gang milling refers to milling operations which
employ two or more cutters—typically of varying size, shape, or width—on the same machine
Arbor. Each cutter can perform the same cutting operation, or a different one, simultaneously,
which produces more intricate designs and complex parts in shorter production times.

2.1.3 Profile milling: Profile milling refers to milling operations in which the machine tool
creates a cut path along a vertical or angled surface on the workpiece. This process
employs profile milling equipment and cutting tools which can be either parallel or
perpendicular to the workpiece’s surface.

2.1.4 Gear cutting: Gear cutting is a milling operation which employs involute gear cutters
to produce gear teeth. These cutters, a type of formed milling cutters, are available in various
shapes and pitch sizes depending on the number of teeth necessary for the particular gear
design. A specialized lathe cutter bit can also be employed by this process to produce gear
teeth.

2.1.5 Other machining processes: Since milling machines support the use of other
machine tools besides milling tools, they can be used for machining processes other than
milling, such as drilling, boring, reaming, and tapping.

CNC Milling Equipment and Components

The CNC milling process employs a variety of software applications, machine tools,
and milling machinery depending on the milling operation being performed.

CNC Support Software

Like most CNC machining processes, the CNC milling process uses CAD software to produce
the initial part design and CAM software to generate the CNC program which provides the
machining instructions to produce the part. The CNC program is then loaded to the CNC
machine of choice to initiate and execute the milling process.

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2.2 CNC Milling Machine Components

Despite the wide range of milling machines available, most machines largely share the same
basic components. These shared machine parts include the:

 Machine interface
 Column
 Knee
 Saddle
 Worktable
 Spindle
 Arbor
 Ram
 Machine tool

Figure 1 – CNC Milling Machine Configurations and Components

2.2.1 Machine interface: The machine interface refers to the machine component the
operator uses to the load, initiate, and execute the CNC machine program.

2.2.2 Column: The column refers to the machine component which provides support and
structure to all other machine components. This component includes an affixed base and can
include additional internal components which aid the milling process, such as oil and coolant
reservoirs.

2.2.3 Knee: The knee refers to the adjustable machine component which is affixed to the
column and provides support to the saddle and worktable. This component is adjustable along
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the Z-axis (i.e., able to be raised or lowered) depending on the specifications of the milling
operation.

2.2.4 Saddle: The saddle refers to the machine component located on top of the knee,
supporting the worktable. This component is capable of moving parallel to the axis of the
spindle, which allows the worktable, and by proxy the workpiece, to be horizontally adjusted.

Worktable: The worktable refers to the machine component located on top of the saddle,
which the workpiece or workholding device (e.g., chuck or vise) is fastened. Depending on the
type of machine employed, this component is adjustable in the horizontal, vertical, both, or
neither direction.

2.2.5 Spindle: The spindle refers to the machine component supported by the column which
holds and runs the machine tool (or arbor) employed. Within the column, an electric motor
drives the rotation of the spindle.

2.2.6 Arbor: The arbor refers to the shaft component inserted into the spindle in horizontal
milling machines in which multiple machine tools can be mounted. These components are
available in various lengths and diameters depending on the specifications of the milling
application. The types of arbors available include standard milling machine, screw, slitting saw
milling cutter, end milling cutter, and shell end milling cutter arbors.

2.2.7 Ram: The ram refers to the machine component, typically in vertical milling machines,
located on top of and affixed to the column which supports the spindle. This component is
adjustable to accommodate different positions during the milling operation.

2.2.8 Machine tool: The machine tool represents the machine component held by the
spindle which performs the material removal operation. The milling process can employ a wide
range of milling machine tools (typically multi-point cutters) depending on the specifications
of the milling application—e.g., the material being milled, quality of the surface finish
required, machine orientation, etc. Machine tools can vary based on the number, arrangement,
and spacing of their teeth, as well as their material, length, diameter, and geometry. Some of
the types of horizontal milling machine tools employed include plane, form relieved, staggered
tooth, and double angle mills, while vertical milling machine tools employed include flat
and ball end, chamfer, face, and twist drill mills. Millings machines can also
use drilling, boring, reaming, and tapping tools to perform other machining operations.

2.3 Milling Machine Considerations

In general, milling machines are categorized into horizontal and vertical machine
configurations, as well as differentiated based on the number of axes of motion.

In vertical milling machines, the machine spindle is vertically oriented, while

in horizontal milling machines the spindle is horizontally oriented. Horizontal machines also
employ arbors for additional support and stability during the milling process, and have support
capabilities for multiple cutting tools, such as in gang milling and straddle milling. Controls
for both vertical and horizontal milling machine are dependent on the type of machine
employed. For example, some machines can raise and lower the spindle and laterally move the
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worktable, while other machines have stationary spindles and worktables which move both
horizontally, vertically, and rotationally. When deciding between vertical and horizontal
milling machines, manufacturers and job shops must consider the requirements of the milling
application, such as the number of surfaces requiring milling and the size and shape of the part.
For example, heavier workpieces are better suited for horizontal milling operations, while die
sinking applications are better suited for vertical milling operations. Ancillary equipment that
modifies vertical or horizontal machines to support the opposing process is also available.

Most CNC milling machines are available with 3 to 5 axes— typically providing performance
along the XYZ axes and, if applicable, around rotational axes. The X-axis and Y-axis designate
horizontal movement (side-to-side and forward-and-back, respectively, on a flat plane), while
the Z-axis represents vertical movement (up-and-down) and the W-axis represents diagonal
movement across a vertical plane. In basic CNC milling machines, horizontal movement is
possible in two axes (XY), while newer models allow for the additional axes of motion, such
as 3, 4, and 5-axis CNC machines. Table 1, below, outlines some of the characteristics of
milling machines categorized by the number of axes of motion.

Table 1 – Characteristics of Milling Machines by Axes of Motion

Note 1: If applicable, “A” indicates advantageous characteristics and “D” indicates
disadvantageous characteristic.

Number of Axes Characteristics

3  Capable of managing most machining needs
 Capable of producing the same products as machines with
more axes
 Suitable for automatic or interactive operation, cutting sharp
edges, drilling holes, milling slots, etc.
 Simplest machine setup (A)
 Only requires one workstation (A)
 Higher knowledge requirements for operators (D)
 Lower levels of efficiency and quality (D)
4  Capable of operating on materials ranging from aluminum and
composite board to foam, PCB, and wood
 Suitable for advertising design, art creating, medical equipment
creating, technology research, hobby prototype building, and
industrial applications
 Greater functionality than 3-axis machines (A)
 Higher levels of precision and accuracy than 3-axis machines
(A)
 More complex machine setup 3-axis machines (D)
 More expensive than machines (D)

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 5  Multiple axes configurations available (e.g., 4+1, 3+2, or 5)
 Suitable for aerospace, architectural, medical, military, oil and
gas, and artistic and functional applications
 Greatest functionality and capabilities (A)
 Depending on config., faster operation than 3-axis and 4-axis
machines (A)
 Highest levels of quality and precision (A)
 Depending on config., slower operation than 3-axis and 4-axis
machines (D)
 More expensive than 3-axis and 4-axis machines (D)

Depending on the type of milling machine employed, the machine tool, the machine worktable,
or both of the components can be dynamic. Typically, dynamic worktables move along the
XY-axes, but they are also capable of moving up and down to adjust the depth of cut and
swivelling along the vertical or horizontal axis for an increased range of cutting. For milling
applications requiring dynamic tooling, in addition to its inherent rotary motion, the machine
tool moves perpendicularly along multiple axes, allowing the tool’s circumference, rather than
just its tip, to cut into the workpiece. CNC milling machines with greater degrees of freedom
allow for greater versatility and complexity in the milled parts produced.

2.4 Types of Milling Machines

There are several different types of milling machines available which are suitable for a variety
of machining applications. Beyond classification based solely on either machine configuration
or the number of axes of motion, milling machines are further classified based on the
combination of their specific characteristics. Some of the most common types of milling
machines include:

 Knee-type
 Ram-type
 Bed-type (or manufacturing-type)
 Planer-type

Knee-type: Knee-type milling machines employ a fixed spindle and vertically adjustable
worktable which rests on the saddle supported by the knee. The knee can be lowered and raised
on the column depending on the position of the machine tool. Some examples of knee-type
milling machines include floor-mounted and bench-type plain horizontal milling machines.

Ram-type: Ram-type milling machines employ a spindle affixed to a movable housing (i.e.,
ram) on the column, which allows the machine tool to move along the XY axes. Two of the
most common ram-type milling machines include floor-mounted universal horizontal and
swivel cutter head milling machines.

Bed-type: Bed-type milling machines employ worktables affixed directly to the machine bed,
which prevents the workpiece from moving along both the Y-axis and Z-axis. The workpiece
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is positioned beneath the cutting tool, which, depending on the machine, is capable of moving
along the XYZ axes. Some of the bed-type milling machines available include simplex, duplex,
and triplex milling machines. While simplex machines employ one spindle which moves along
either the X-axis or Y-axis, duplex machines employ two spindles, and triplex machines
employ three spindles (two horizontal and one vertical) for machining along the XY and XYZ
axes, respectively.

Planer-type: Planer-type milling machines are similar to bed-type milling machines in that
they have worktables fixed along the Y-axis and Z-axis and spindles capable of moving along
the XYZ axes. However, planer-type machines can support multiple machine tools (typically
up to four) simultaneously, which reduces the lead time for complex parts.

Some of the specialized types of milling machines available include rotary table, drum, and
planetary milling machines. Rotary table milling machines have circular worktables which
rotate around the vertical axis and employ machine tools positioned at varying heights for
roughing and finishing operations. Drum milling machines are similar to rotary table
machines, except the worktable is referred to as a “drum” and it rotates around the horizontal
axis. In planetary machines, the worktable is stationary, and the workpiece is cylindrical. The
rotating machine tool moves across the surface of the workpiece cutting internal and external
features, such as threads.

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 CHAPTER-3

Material Considerations
The CNC milling process is best suited as a secondary machining process to provide finishing
features to a custom-designed part, but can also be used to produce custom designs and
specialty parts from start to finish. CNC milling technology allows the process to machine parts
of a wide range of materials, including:

 Metals (including alloy, exotic, heavy duty, etc.)

 Plastics (include thermosets and thermoplastics)
 Elastomers
 Ceramics
 Composites
 Glass

As with all machining processes, when selecting a material for a milling application, several
factors must be considered, such as the properties of the material (i.e., hardness, tensile and
shear strength, and chemical and temperature resistance) and the cost-effectiveness of
machining the material. These criteria dictate whether the material is suitable for the milling
process and the budgetary constraints of the milling application, respectively. The chosen
material determines the type(s) of the machine tool(s) employed and its/their design(s), and the
optimal machine settings, including cutting speed, feed rate, and depth of cut.

3.1 Alternatives

CNC milling is a mechanical machining process suitable for machining a wide range of
materials and producing a variety of custom-designed parts. While the process may
demonstrate advantages over other machining processes, it may not be appropriate for every
manufacturing application, and other processes may prove more suitable and cost-effective.

Some of the other more conventional mechanical machining processes available include
drilling and turning. Drilling, like milling, typically employs multi-point tools (i.e., drill bits),
while turning employs single-point tools. However, while in turning the workpiece can be
moved and rotated similar to that of some milling applications, in drilling the workpiece is
stationary throughout the drilling operation.

Some of the non-conventional mechanical machining processes (i.e., do not employ machine
tools but still employ mechanical material removal processes) include ultrasonic machining,
waterjet cutting, and abrasive jet machining. Non-conventional, non-mechanical machining
processes—i.e., chemical, electrical, and thermal machining processes—provide additional
alternative methods of removing material from a workpiece which do not employ machine
tools or mechanical material removal processes, and include chemical milling, electrochemical
deburring, laser cutting, and plasma arc cutting. These non-conventional machining methods
support the production of more complex, demanding, and specialized parts not typically
possible through conventional machining processes.
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 Chapter 4:

Operation of CNC Milling:

4.1 Machine Power-On

This section tells you how to power-on a new machine for the first time.
1. Press [POWER ON] until you see the Haas logo on the screen. After a self-test and boot
sequence, the display shows the startup screen. The startup screen gives basic instructions to
start the machine. Press [CANCEL] to dismiss the screen.

2. Turn [EMERGENCY STOP] to the right to reset it.

3. Press [RESET] to clear the startup alarms. If you cannot clear an alarm, the machine may
need service. Contact your Haas Factory Outlet (HFO) for assistance.
4. If your machine is enclosed, close the doors.
WARNING: Before you do the next step, remember that automatic motion begins immediately
when you press [POWER UP]. Make sure the motion path is clear. Stay away from the spindle,
machine table, and tool changer
5.Press [POWER UP].

After the first [POWER UP], the axes move toward their home positions. The axes then move
slowly until the machine finds the home switch for each axis. This establishes the machine
home position.

Press any of the following:

a. [CANCEL] to dismiss the screen.
b. [CYCLE START] to run current program.
c. [HANDLE JOG] for manual operation

4.2 Spindle Warm-Up

If your machine’s spindle has been idle for more than (4) days, run the spindle warm-up
program before you use the machine. This program brings the spindle up to speed slowly to
distribute the lubrication and let the spindle reach a stable temperature. Your machine includes
a 20-minute warm-up program (O09220) in the program list. If you use the spindle at consistent
high speeds, you should run this program every day.

.
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4.3. Device Manager Operation
Press [LIST PROGRAM] to access the device manager. The initial device manager display
shows the available memory devices in a tabbed menu. These devices can include machine
memory, the User Data directory, USB memory devices connected to the control, and files
available on the connected network. Select a device tab to work with the files on that device.

: Device Manager Initial Screen Example: [1] Available Device Tabs, [2] Search Box, [3]
Function Keys, [4] File Display, [5] File Comments (only available in Memory).

Use the cursor arrow keys to navigate the directory structure:

• Use the [UP] and [DOWN] cursor arrow keys to highlight and interact with a file or a
directory in the current root or directory.

• Roots and directories have a right-hand arrow character (>) in the far-right column of the file
display. Use the [RIGHT] cursor arrow key to open a highlighted root or directory. The display
then shows the contents of that root or directory.

• Use the [LEFT] cursor arrow key to return to the previous root or directory. The display then
shows the contents of that root or directory

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• The CURRENT DIRECTORY message above the file display tells you where you are in the
directory structure; for example: MEMORY/CUSTOMER 11/NEW PROGRAMS shows that
you are in the subdirectory NEW_PROGRAMS inside the directory CUSTOMER 11, in the
root of MEMORY.

4.4 File Display Columns

When you open a root or directory with the [RIGHT] cursor arrow key, the file display shows
you a list of the files and directories in that directory. Each column in the file display has
information about the files or directories in the list.
F4.2: Program/Directory List Example

The columns are:

• File selection check box (no label): Press ENTER to toggle a check mark on and off in the
box. A check mark in a box indicates that the file or directory selected for operations on
multiple files (usually copy or delete).
• Program O Number (O #): This column lists the program numbers of the programs in the
directory. The letter ‘O’ is omitted in the column data. Only available in the Memory tab.
• File comment (Comment): This column lists the optional program comment that appears in
the first line of the program. Only available in the Memory tab.
• File Name (File Name): This is an optional name that the control uses when you copy the file
to a memory device other than the control. For example, if you copy program O00045 to a
USB memory device, the filename in the USB directory is NEXTGENtest.nc.
• File Size (Size): This column shows the amount of storage space that the file takes up.
Directories in the list have the designation <DIR> in this column.
• Date Last Modified (Last Modified): This column shows the last date and time when the file
was changed. The format is YYYY/MM/DD HR:MIN.
• Other Information (no label): This column gives you some information about a file’s status.
The active program has an asterisk (*) in this column. A letter E in this column means that the
program is in the program editor. A greater-than symbol (>) indicates a directory. A letter S
indicates that a directory is part of Setting 252 (refer to page 396 for more information). Use
the [RIGHT] or [LEFT] cursor arrow keys to enter or exit the directory.

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 CHAPTER-5
CREATE A NEW PROGRAM

Press [INSERT] to create a new file in the current directory. The CREATE NEW
PROGRAM popup menu shows on the screen:

F5.1: Create New Program Popup Menu Example: [1] Program O number field, [2] File Name
field, [3] File comment field.

Enter the new program information in the fields. The Program O number field is required;
the File Name and File comment are optional. Use the [UP] and [DOWN] cursors to move
between the menu fields.
Press [UNDO] at any time to cancel program creation.
• Program O number (required for files created in Memory): Enter a program number up to
(5) digits long. The control adds the letter O automatically. If you enter a number shorter than
(5) digits, the control adds leading zeros to the program number to make it (5) digits long; for
example, if you enter 1, the control adds zeros to make it 00001.

NOTE: Do not use O09XXX numbers when you create new programs. Macro programs often
use numbers in this block, and overwriting them may cause machine functions to malfunction
or stop working.
• File Name (optional): Type a filename for the new program. This is the name the control uses
when you copy the program to a storage device other than memory.
• File comment (optional): Type a descriptive program title. This title
program as a comment in the first line with the O number. Press [ENTER] to save your new
program. If you specified an O number that exists in the current directory, the control gives the
message File with O Number nnnnn already exists. Do you want to replace it? Press [ENTER]
to save the program and overwrite the existing program, press [CANCEL] to return to the
program name popup, or
press [UNDO] to cancel.

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5.1 Select the Active Program
Highlight a program in the memory directory, then press [SELECT PROGRAM] to make the
highlighted program active. The active program has an asterisk (*) in the far-right column in
the file display. It is the program that runs when you press [CYCLE START] in
OPERATION:MEM mode. The program is also protected from deletion while it is active

5.2 Check Mark Selection

The check box column on the far left of the file display lets you select multiple files. Press
[ENTER] to place a check mark in a file’s check box. Highlight another file and press
[ENTER] again to put a check mark in that file’s check box. Repeat this process until you have
selected all of the files you want to select.
You can then do an operation (usually copy or delete) on all of those files at the same time.
Each file that is part of your selection has a check mark in the check box. When you choose an
operation, the control does that operation on all of the files with check marks.
For example, if you want to copy a set of files from the machine memory to a USB memory
device, you would put a check mark on all of the files that you want to copy, then press [F2]
to start the copy operation. To delete a set of files, put a check mark on all of files you want to
delete, then press [DELETE] to start the delete operation.

NOTE: A check-mark selection only marks the file for further operation; it does not make the
program active.

NOTE: If you have not selected multiple files with check marks, the control does operations
only on the currently highlighted directory or file. If you have selected files, the control does
operations only on the selected files and not on the highlighted file, unless it is also selected.

5.1.4 Copy Programs

This function lets you copy programs to a device or a different directory.
1. To copy a single program, highlight it in the device manager program list and press
[ENTER] to assign a check mark. To copy multiple programs, check-mark all the programs
you want to copy.
2. Press [F2] to start the copy operation.
Operation 87
The Select Device popup appears

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3. Use the cursor arrow keys to select the destination directory. [RIGHT] cursor to enter the
chosen directory.
The Insert Directory: Copy popup menu appears
F5.2: Copy Popup Menu Example

4. Press [ENTER] to complete the copy operation, or press [CANCEL] to return to the device
manager.
5.2.1 Edit a Program
Highlight a program, and then press [ALTER] to move the program into the program editor.
The program has the designation E in the far-right column of the file display list when it is in
the editor, unless it is also the active program. You can use this function to edit a program while
the active program runs. You can edit the active program, but your changes do not take effect
until you save the program and then select it again in the device manager menu
5.2.2 File Commands
Press [F3] to access the file commands menu in the device manager. The list of options appears
under the File [F3] drop-down menu in the device manager. Use the cursor arrow keys or the
jog handle to highlight a command, and then press [ENTER].
F5.3: The File Commands Menu

•Make Directory: creates a new subdirectory in the current directory. Type a name
for the new directory, and then press [ENTER].
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• Rename: changes the name of a program. The Rename popup menu has the same options as
the new program menu (File Name, O Number, and File Title).
• Delete: deletes files and directories. When you confirm the operation, the control deletes the
highlighted file, or all of the files with check-mark selection.
• Duplicate Program: makes a copy of a file in the current location. The Save As popup menu
asks you to specify a new program name before you can complete this operation.
• Select All: adds check-marks to all of the files/directories in the Current Directory.
• Clear Selections: removes check-marks from all of the files/directories in the Current
Directory.
• Sort By O Number: sorts the program list by O number. Use this menu item again to sort by
filename. By default, the program list is sorted by filename. Only available in the Memory tab.
• Setting 252 add / Setting 252 remove: adds or removes a custom
sub-program search location to the list of locations. See Setting Up Search Locations section
for more information.
• Setting 262 DPRNT: adds a custom destination file path for DPRNT
• Get File Path: places the path and the name of the selected file in parenthesis on the input
bar.
• Special Symbols: accesses text symbols that are not available on the keyboard. Enter the
number of the character you want to use to put it in the input bar. The special characters are: _
^~{}\|<>

4.4 Full Machine Backup

The backup function makes a copy of your machine’s settings, programs, and other data so that
you can easily restore them. You create and load backup files with the System [F4] drop-down
menu.
F4.7: [F4] Menu Selections

To create a full machine backup:

1. Press [LIST PROGRAM].
2. Navigate to the USB or Network Device.
3. Press [F4].
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4. Select Backup Machine and press [ENTER].
Full Machine Backup
Backup Machine Pop-up Menu

5. Highlight the data to back up and press [ENTER] to apply a check mark. Press [F2] to select
all data. Press [F3] to clear all check marks.
6. Press [F4]. The control saves the backup you selected in a zip file labelled.

T5.3: Default File Names in the Zip File

Selected Data Saved Name of File (Folder)
Backup

System Data Settings (Serial Number)

System Data Offset OFFSETS.OFS
System Data Alarm History AlarmHistory.txt
System Data Advanced Tool ATM.ATM
Management (ATM)
System data Key History KEY HISTORY
Programs Memory Files and Folders (MEMORY)
User data User Data Files and (User Data)
Folders

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 CHAPTER-6
Basic Program Search

You can use this function to quickly find code in a program.

NOTE: This is a quick-search function that finds the first match in the search direction that
you specify. You can use the Editor for a more full-featured search. Refer to page 119 for more
information on the Editor search function.
1. Type the text you want to find in the active program.
2. Press the [UP] or [DOWN] cursor arrow key.
The [UP] cursor arrow key searches from the cursor position to the start of the program. The
[DOWN] cursor arrow key searches to the end of the program. The control highlights the first
match.

6.1 Tooling
This section describes tool management in the Haas control: commanding tool changes, loading
tools into holders, and Advanced Tool Management.

6.2 Tool Holders

There are several different spindle options for Haas mills. Each of these types requires a
specific tool holder. The most common spindles are 40- and 50-taper. 40-taper spindles are
divided into two types, BT and CT; these are referred to as BT40 and CT40. The spindle and
tool changer in a given machine are capable of holding only one tool type.
Tool Holder Care
1.Make sure that tool holders and pull studs are in good condition and tightened together
securely or they may stick in the spindle.

2. Clean the tool holder taper body (the part that goes into the spindle) with a lightly oiled rag
to leave a film, which helps prevent rusting.
Pull Studs
A pull stud (sometimes called a retention knob) secures the tool holder into the spindle. Pull
studs are threaded into the top of the tool holder and are specific to the type of spindle. Refer
to the 30, 40, and 50-taper spindle and tooling information on the Haas Resource Center
website for descriptions of the pull studs you need.

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 CHAPTER-7

CNC MILLING OPERATION SAFETY’S

At Lowell using CNC machines is part of the daily routine, but it is extremely important that
everyone remembers the proper safety rules while operating the machines. This will be a
rundown of the basic safety rules that should be followed while working with or around a
CNC machine. The two first general rules for CNC machine operation are 1. You should
never work with a CNC machine without the proper training or the correct operator’s manual
and 2. You should never try to program a CNC machine without the proper training as well.

fitted in place at all CNC machines are built with the proper safety devices in place. These
may include guards and other protective devices, it is important that these safety devices are
firmly times while the machine is in use. Some of these safety devices may include

 An Emergency Stop Button

The emergency stop button is used to shut down the machine instantly. This button is
located on the handheld unit, the control panel, and other places on the machine.
 A Soundproof Casing
The soundproof casing reduces the noise emitted by the operating section of the
machine. It also protects the machine operator from the risk of flying tool fragments
and any other flying objects.
 The Curtain Guards
The curtain guards are made out of PVC. These are designed to shield the machine
operator from the risk of tool fragments or airborne chips.
 The Guard Fence
This part marks the maximum working area of the machine. This fence keeps the
machine operator away from any moving parts.
 The Contact Mats
The operator uses this control to stop the CNC machine instantly. When he or she
stands on the mat the machine stops instantly. This protects the operator from the
moving parts.

There is also a list of personal rules that should also be followed outside of understanding the
basic safety functions of the machines. You can feel free to add any additional rules that you
think may apply to you and your coworkers. Commented [BN1]:

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7.1 DO;

 Always ensure that you wear proper ear protection and a good pair of safety glasses
when operating a CNC machine.
 Ensure that your safety glasses are firmly in place every time you are closely
observing the cutting tools.
 Ensure that you wear suitable footwear such as safety boots at all times.
 If you have long hair, ensure that you keep it covered when you operate the CNC
machine.
 Keep your hands away from any moving parts during machining processes.
 Stand clear of the machine whenever it is operational. You should also warn any other
people near the risk of being too close to it.
 Whenever you are handling or passing tools, avoid touching the cutting edges.
 Ensure that you turn the machine off completely and clean it whenever you have
finished using it.

7.2 DON’T’S;

 You should never wear gloves while operating the CNC machine.
 You should never wear jewelry or any loose clothing.
 You should never try to reach into the machine while it’s running
 You should never put your hands anywhere near the spindle when it’s revolving.
 Never leave the machine when it’s not completely powered down.

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