Revision as of 05:28, 8 April 2013

Equipment / CNC Model Mill

A model mill for 3D subtractive prototyping, 3D scanning and PCB milling.

Our Roland MDX-40A Model Mill

Summary

The MDX-40A is a full-featured CNC (computer numerical control) mill capable of cutting jeweler's wax, resins, chemical wood, acrylic and wood. It is ideal for quickly and easily creating high-quality prototypes, parts and models.

http://www.rolanddga.com/products/milling/mdx40/

• Capacity: 305 x 305 x 105mm
• Rate (X,Y): 50mm/sec
• Rate (Z): 30mm/sec
• Spindle Speed: 4500 to 15000rpm
• Resolution: 0.01mm
• Materials: Plastics (ABS, Delrin/Acetal, Nylon, Acrylic), tooling board, wood, and modeling wax, PCBs
• Includes scanning head

Here are some examples we've made on the Model Mill (please add a photo of yours any time you do a job!)

Using the Mill

Owners

The Owners are those who have volunteered to be in charge of the equipment, organising maintenance, training others to use it, and generally being a point of contact. The current Owners of this item are:

• Stephen Woolhead
• Brian Corteil
• Uwe Borowski

If you have any questions, problems or concerns around the laser cutter, please use the mailing list thread:

• Log : MDX40 Model Mill

Training

To get trained on the model mill and be added to the qualified user list, you will need to arrange for a training session with one of the Model Mill Owners.

If you'd like to arrange training, please see:

• Model Mill Training

Health and Safety

COMMING SOON

Instructions

Product Manual

Coordinate Systems

The main window in VPanel displays the present location of the tool as numerical values. Using these lets you perform manual feed accurately, which can be very convenient in tasks such as aligning the workpiece.

The numerical values that indicate the location of the tool are called "coordinates," and the starting point for the coordinates is called the "origin." The following figure shows a location that is shifted from the origin by 50 millimetres along the X-axis, 30 millimetres along the Y-axis, and 20 millimetres along the Z-axis. This X-axis distance is called the "X-axis coordinate" (or sometimes just the "X coordinate"), and the Y- and Z-axis distances are similarly called the "Y-axis coordinate" and the "Z-axis coordinate."

The distances from the origin for the respective axes to the tool are therefore the corresponding coordinate values.

Coordinate Systems

It is possible to select the coordinate system that is used to display the tool location in VPanel. The selection made here only determines the method used to display coordinates.

With the actual origin point, you need to perform the setting individually for the coordinate system that is used with the cutting data. It is a good idea to leave the selection at "User Coordinate System" as this is the system used by most programs.

• User Coordinate System: This is a coordinate system in which the location of the origin point can be freely changed.
• Machine Coordinate System: This is a machine-specific coordinate system in which the location of the origin point is fixed and cannot be changed.

Pausing/Resuming/Quitting of Cutting

This operation pauses cutting. You perform it using the built-in panel. This also makes it possible to resume cutting at the paused position after an operation such as moving the tool to check the status of the workpiece.

Press the VIEW button during cutting. Rotation of the spindle stops, and the tool moves to the VIEW position. While movement of the tool and table is in progress, the VIEW lamp flashes, and after the movement is completed, the lamp lights up.

It is possible to open the front cover while the machine is paused. Before opening the front cover, make sure that the cutting operation stopped completely and that the VIEW lamp is lit.

Press and hold the VIEW button. The tool returns to the position where operation was paused, and cutting resumes. After the tool starts moving, the VIEW lamp flashes until cutting is resumed. When cutting is resumed, the VIEW lamp goes dark.

If you open the front cover while the operation is paused, close the front cover, then perform the operation to resume.

Tool Selection

Select a tool matched to the purpose. It's a good idea to use the tools selectively, according to the work process (such as rough cutting or finish cutting) and the design.

Cutters is an all-inclusive term used to describe the rotating cutting tools used. Cutters can be manufactured from high speed steel or carbide and are available in a variety of configurations for specific applications.

• End mill
  • Straight end mill: The end cutting edge is flat-shaped. It is suitable for fashioning a flat surface or steps.
  • Ball end mill: The end cutting edge is ball-shaped. It is suitable for fashioning a curved surface or waveform.
• Engraving cutter
  • Character cutter: This tool is suitable for engraving in general with broad versatility. It is appropriate for character engraving on the plate.
  • Parallel cutter: This cutter is suitable for engraving wide surfaces. This cutter enables engraving large characters and surface leveling (to flatten the surface of the material) of the table where the material is placed. Because both sides have a cutting blade, it is not possible to make a deep cut in the Z-axis direction.

Software

VPanel

VPanel is a program to operate the modelling machine on the computer screen. It has functions to output cutting data, perform maintenance, and make various corrections. In addition, it displays error messages of the modelling machine.

ClickMill

ClickMILL is a program that lets you perform simple milling operations without a model (3D shape data). It allows you to perform drilling, chamfering and surface levelling and to cut flat panels to size in rectangular or circular shapes.

SRP Player

SRP Player imports a model (3D data in IGES, DXF [3D], and STL) and cuts a workpiece to transform it into the actual shape. It calculates the path of the blade that performs the cutting, and operates a cutting machine accordingly. The path of the blade is called the "tool path".

Basic Introduction to SRP Player (Video) Note: We do not have the Rotary axis or the tool changer.

Cut2D

Manufacture's site for Cut2D

Cut2D is easy to use. The software automatically compensates for the cutter diameter and geometry when calculating toolpaths, so you simply select the shapes to machine and Cut2D takes care of the rest.

Cut2D opens CAD drawings and vector designs from most drawing packages and includes filters for the following industry standard file formats: DXF, DWG, EPS, AI & PDF files

Very simple projects can also be drawn directly in Cut2D.

Multiple designs can be imported and combined.

Cut2D allows the you to preview the calculated tool paths in a 3D window to see exactly what the machined part will look like.

Cut2D Tutorials These tutorials are very good and are your best resource for learning how to use this software.

CopperCAM

Manufacture's site for CopperCAM

An essential part of producing milled printed circuit boards is the ability to convert the Gerber photoplot files produced by most PCB layout tools to a format readable by CNC mill software to either isolate traces and pads or to "rub out" all copper on a board except traces and pads. You also need a tool to convert the common Excellon drill files to CNC language to drill the through holes and vias in the circuit board.

CopperCAM is a program for engraving and isolation routing. It only provides the Gerber and drill file conversion and does not provide any machine control. The exported files should be loaded and run via the vPanel software for download to the mill.

Tips & Tricks

COMMING SOON

Maintenance

The maintenance of the Model Mill is carried out by the Owners, with some basic maintenance being carried out by Users on every job.

Maintenance Schedule

Continuous Maintenance (Every job, done by all Model Mill Users)

• Hover all the inside of the mill, and under it. Do not blow the dust, it goes everywhere!
• Clean the mill with a
• Clean any debris off laser bed and surround using soft brush

Basic Maintenance (done by Model Mill Maintainers)

• STUFF TO GO HERE

Maintenance Log

Installed on 21st March 2013.

Maintenance Shopping List

Further Information

Installation

Purchase

• MP-ROTO-MDX40AE (mill - £4,695)
• RL-ROTO-TS30SCAN (scanner head - £295)
• Selection of tooling (???)
• Sample selection of materials (???)

Repairs

Expected on-going maintenance costs are expected to be very low if maintained correctly. Two areas that will need watching for repair are:

• Spindle drive belt expected life 1000's of Hours (Supplier holds in stock) ~£10
• Spindle assembly (bearings fail) 10000 Hours MTBF (Supplier holds in stock) £195. It is suggest that when this starts to fail we buy a second spindle assembly and then repair the first, the bearings can be had for <£20.

Material Suppliers

Related Machines

Here are other machines available in this class: