VERSION 3.1

MATSUURA 5-AXIS MILL

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3.0MACHINE

CONTROLS

THE MATSUURA MILL IS CAPABLE OF MAKING ACCURATE FIVE-AXIS PARTS.

TOOL CAROUSEL

ALLOWED MATERIALS + Metal + Plastic

BANNED MATERIALS + Wood + Carbon fiber and composites

SEE SHOP STAFF FIRST + All other materials

MATERIALS

CONTROLLER

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PROTECT YOUR EYES FROM FLYING CHIPS.

NEVER OPEN THE DOOR WHEN THE SPINDLE IS ROTATING.

KEEP IT SAFE

USE PERSONAL PROTECTIVE EQUIPMENT WHEN OPERATING THE MILL.

Opening the door when the spindle is rotating is extremely dangerous, and will result in the loss of machining privileges.

Always wear safety glasses.

TAKE PRECAUTIONS WHEN HANDLING SHARP OR HEAVY ITEMS.

The tooling is sharp and can be heavy.Wear cut resistant gloves and ask for assistance if needed.

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3.0CONTROLLER &

DISPLAY

UNDERSTANDING THE CONTROLLER AND DISPLAY PANEL.

CONTROLLERYou run the mill with the controller.1. USB insert2. Reset button3. Job Select key switch4. Power On & Power Off buttons5. E-stop6. Touch screen display7. Keyboard8. Control panel keys9. Edit key switch10. Feed Hold & Cycle Start11. Light switch

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DISPLAYThe mill uses a touch screen that changes based on the category you’ve selected.

1. Status bar + Displays alarms, lights, and overdue

maintenance items.2. Category display area

+ The three categories are Running, Setup, and Maintenance.

3. Sub-category icons + The icons that appear under each

category are sub-categories. + Example: Program Manager is a sub-

category of Running.4. Category commands5. Sub-category commands6. Main screen

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3.0CONTROL PANEL

KEYS

UNDERSTANDING THE CONTROL PANEL KEYS.

CONTROL PANELThe control panel for the mill is laid out in groups of keys that have related functions.1. E-stop2. Power On and Power Off3. Coolant on/off4. Door unlock5. Tool clamp/unclamp6. Jog Increments7. Jog handle8. Function key switch9. Mode buttons10. Axis selector11. Rapid & Feed Rate Override Dials12. Feed Hold & Cycle Start

KEYS AND MODESThe Function key switch is a safety measure.

+ Select Set Up when changing tools or jogging.

+ Select Auto when pressing Cycle Start to execute MDI commands or starting a program.

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STEPS FOR SUCCESSFUL USETo make a part, you need to complete each step in order. 1. Verify file in CAMplete.2. Start up the mill.3. Load stock.4. Check Work Coordinate System.5. Set the Tool Length Offsets.6. Load the program.7. Run the program.8. Clean up.

MACHINE SPECIFICATIONSThe Matsuura MX-330 CNC mill is a large, powerful mill with the following specifications:

+ Five axes (X, Y, Z, A, and C) + 20,000 RPM maximum spindle speed + High pressure through-spindle coolant + Traverse (rapid relocation) speed up to 1,570 inches per minute

On Pier 9 you must not use higher than 10% rapid for an unproven program so you have time to react if something goes wrong.

A reduced rapid speed will not change the cutting speed. + Maximum work envelope of 13” diameter by 10” tall + Tool carousel can hold up to 60 tools

OVERVIEW

FOLLOW ALL THE STEPS, IN ORDER.

REQUIRED FOR USEBefore you start your work, make sure you have the following materials:

+ An .nc file from CAMplete with no simulation errors + A thumb drive or Filezilla Client software to load the .nc file onto the mill + A copy of this Quick Start Guide

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3.0FINAL VERIFICATION

ENSURE THE FINAL SIMULATION IS ACCURATE.

VERIFY FILE IN CAMPLETESafe use of the Matsuura MX-330 requires that all CAM files be accurate. This ensures that simulation data in CAMplete is trustworthy. Before going through this checklist, cut your stock and measure it. This is critical when probing doesn’t occur.

CAMplete checkFollow the steps in the CAMplete Instructable.1. Ensure that you are using the Autodesk

CAM APT loader.2. Check that the NC Format and Machine

Definition are correct.3. Ensure your G-code coordinate system has

been translated on the Z-axes by 52 mm.4. Use Collision Checking simulation mode.5. Ensure simulation checks and tolerances

are correct. Proximity All tolerance should be no

smaller than 0.25”. 6. Check Status bar after simulation to ensure

there are no red error messages.7. Export G-code.

Use USB for smaller files. Use Filezilla for 3D or 5-axis files.

CAM file + Update your stock size to reflect actual stock size. + Ensure that you are using the latest Pier 9 Matsuura Mill Tool Library.

The current library is recorded on the front of the machine and can be downloaded from the Pier 9 CNC Data Instructable.

+ Tools are marked with a number that corresponds to their number in the CAM software.

+ Ensure that your workholding model is accurate and your part is correctly placed inside the stock.

+ If the vise jaws will be open 3.5” or more, use a workholding file with jaws facing out.

+ Double check that the WCS, G54 home, is placed on the center top of the Lang receiver plate.

+ If you need to use custom tools, check in with CNC shop staff. They will prepare a digital tool library for you and insert custom tools into the machine.

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START UP THE MILL1. Turn the MAIN POWER switch on

the back of the machine. Red means that the machine

is on. Light above switch will turn on.

2. Press the green POWER ON switch.

Wait for the computer to boot up.

3. Reset the E-Stop by rotating clockwise.

4. Press the green POWER ON switch.

The alarm will be deactivated.

Warm up the spindleIf the mill has not been run today, you’ll need to run the spindle warm-up program.1. Press MEM.2. Turn key to Auto.3. Select Program Manager under the

Running category.4. Select Path 2 under User.5. Select Pier 9 Warmup.6. Select Open.

STARTUP

CORRECTLY STARTING UP THE MILL.

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7. Press CYCLE START to run the program. This takes about 10 minutes.

PRESSING CYCLE START WILL RESULT IN MACHINE MOVEMENT WHEN KEY IS SET TO AUTO.

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CoordinatesThe Matsuura uses three diffferent coordinate systems. You’ll use the Absolute coordinate system for your part.1. On the screen under the Running

category, select NC Operation.2. Select Current Position.3. Select All.4. Note the current coordinates.

Relative= Set to a convenient location by operator

Absolute= Work Coordinate System (G54)

Machine= Machine Coordinate System (G53)

AXES AND COORDINATES

UNDERSTANDING THE AXES AND COORDINATES.

Axes + The Matsuura has three linear

axes (X, Y, and Z). + There are two rotational axes (A

and C). + The 4th Axis, (A), rotates around

the X axis. + The 5th Axis, (C), rotates around

the Z axis.

TRUNNION MACHINING PLATTER

LANG RECEIVER

PLATE

A AXIS (4TH) C AXIS (5TH)

ADAPTOR PLATE

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3.0JOGGING AND

HOMING

MOVING THE SPINDLE AND TRUNNION.

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JoggingWhen jogging, you’ll need to set the axis and the increment - how far the spindle or trunnion moves for each click of the jog handwheel.1. Press HAN.2. Turn key to SET UP.3. Select an axis with the Axis Selector.

Axis 4 and 5 are locked by default. To unlock 4 and 5, press the Axis

Unclamp buttons.4. Select an increment.

X1= 0.0001” X10= 0.001” X100= 0.01”

5. Rotate the jog handwheel clockwise to move in the positive direction and counterclockwise for negative.

If you reach a soft limit, an alarm will appear on the Display screen.

Press the white Reset button on the top left corner of the keyboard.

Turn the jog handwheel in the opposite direction to clear the alarm.

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HomingFollow these steps to return any axis to Machine Home (G53 0, 0, 0, 0, 0). The spindle will be fully retracted with the machining platter as far front and left as possible. 1. Press the crosshairs button for Home mode. 2. Turn the Rapid Rate to 10%.3. Select an axis.4. Press the Plus button under the Axis Selector.

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LOAD STOCKInstall vise in machine. 1. Press Door Unlock.2. Carefully wipe chips from receiver plate and bottom of vise.3. Set vise on receiver plate.4. Tighten front bolt to 30 Newton-meters using a torque

wrench.

LOAD STOCK AND CHECK WCS

INSTALL WORK IN VISE AND CHECK WORK COORDINATE SYSTEM.

Install stock in vise1. Ensure 4th and 5th axes are locked.2. Center stock in vise.

Lang vises have tick-marks on the front edges of the jaws which can be used as a reference.

3. Tighten to 100 Newton-meters (70 Foot-pounds) using a torque wrench.

Lang 3-jaw chucks should not be tightened more than 70 Newton-meters (50 Foot-pounds).

4. Close the door.

CHECK WORK COORDINATE SYSTEMBecause Work Home is set to the top center of the Lang receiver plate, you don’t need to probe your stock. As long as the receiver plate is not moved for a custom project, G54 will not change.

+ Follow these steps to ensure the G54 coordinates inside the machine are correct.

1. On display, under Running, select Work Crd.2. Ensure G54 has a green check next to it.3. Compare the G54 (X, Y, and Z) coordinates with the numbers

recorded outside the machine. If the numbers are different, consult shop staff. Take a picture of G54 on the controller so that you can

ensure consistency for multiple-day operations.

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SET THE TOOL LENGTH OFFSETSMatsuura library tools are stored inside the tool carousel. Before running a program, you will call up each tool to verify the number and measure the tool length offset.

TOOL OFFSETS

INSPECT LIBRARY TOOLS AND SET TOOL LENGTH OFFSETS.

Perform a tool change1. Press MDI.2. Turn key to AUTO. 3. On display, under Running, select NC Opera.4. Type T[tool number]M6.

The G-code will appear in the command line. 5. Press EOB.6. Press INSERT.

The G-code will move to the program section of the screen.

7. Turn the Rapid Rate to 10%.8. Press CYCLE START.

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Check tool.Verify that the tool in the machine is the same as the one in the library.1. Press Door Unclamp and open door.2. Check the tool number engraved on the tool holder.

If the tool numbers do not match, check with shop staff.

3. Close door.

Measure tool.1. Type G101.

This command will measure the tool currently in the spindle.

You will use G101 for every tool in your program.2. Press EOB.3. Press INSERT.4. Press CYCLE START.

The machine will use a laser to measure the length of the tool.

Repeat these steps for each tool in your program.

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INSERT

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3.0LOAD PROGRAM

TRANSFER PROGRAM AND PREPARE TO RUN MILL.

LOAD PROGRAMFollow these steps to transfer your program to the machine.1. Press MEM.

MEM mode is used to run programs.2. Insert USB into controller on left side of

screen.3. On the display, under Running, select

Program Mgr.4. On left side of screen, select Data_SV.5. Select Input.6. Highlight your program.7. Select OK.

Green text “Executing” will appear while program is transferring.

Program will transfer to Data Server. This can take a while. For larger

programs, use Filezilla File Transfer Protocol software.

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PRE-RUN CHECKLISTYou're ready to run the program. Double check that these tasks have been completed.

+ Stock is measured and updated in CAM software.

+ There are no errors in CAMplete. + All tools are loaded in machine. + Tool length offsets have been measured. + The Work Coordinate System (G54) is

correct. + Stock is centered in the vise. + Correct torque was used to attached vise to

platter. + Correct torque was used to tighten vise

jaws.

Using coolantBecause of the spindle's high speed and feed rate, coolant is required.

Flood coolant will automatically be turned on after every tool change.

To disable flood coolant for a dry run, use dry run mode (red button).

Toggle flood coolant on and off to increase visibility while tool is descending in Z.

Use through spindle coolant for deep pockets and holes.

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THROUGH SPINDLE

COOLANT

FLOOD COOLANT

DRY RUN MODE

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3.0RUN PROGRAM

RUN PROGRAM AND MID-PROGRAM PROCEDURES.

Inspecting part during program + If you need to inspect your part mid-program, you must turn

off the spindle before opening the door.1. Press FEED HOLD.2. Press HAN.3. Turn spindle off.4. Turn coolant off.5. Press Door Unlock.6. Open door, check part, and close door. 7. Turn spindle on.8. Press MEM.9. Turn coolant on.10. Press CYCLE START.

While program is running + While looking through the wiper viewport, keep one hand

on Feed Hold and the other on Feed Rate. + Use Single Block (SBK) after each tool change.

Turn off before tool begins cutting. + Turn off coolant when needed to verify tool length offset. + Change Rapid Rate to 1% and Watch Distance to Go in Z

on the main screen to verify tool length offset. + Use FEED HOLD or Feed Rate at 0% to pause the machine. + Press Feed Hold and Rewind to reset to the beginning of

the program.

DISTANCE TO GO

RUN PROGRAM1. Press MEM.2. Highlight program in Data Server.

Data Server is under Running/Program Manager.

3. Select OPEN4. Turn Rapid Rate to 10%.5. Turn Feed Rate to 0%.

When Feed Rate is 0%, neither the spindle nor the trunnion will move, even for rapid moves.

6. Switch key to AUTO.7. Press CYCLE START.

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PRESSING CYCLE START WILL RESULT IN MACHINE MOVEMENT WHEN KEY IS SET TO AUTO.

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3.0CLEANUP

PLAN ON 30 MINUTES TO CLEAN THE MILL.

CLEAN UP Run the Goodnight Program.1. On the Display, under Running, select Program Mgr.2. Select Path 2 and highlight Goodnight Pier 9.3. Select Open.4. Press CYCLE START.

Clear chips.1. Wipe chips from machining platter, vise, and trunnion with a

red rag. Do not use compressed air.

2. Walk around to the back of the machine and empty chip bins into the Haas Mill chip container.

Do not put chips into metal recycling.

Final Steps.1. Remove USB from controller.2. Press E-stop.3. Switch key to SETUP.4. Press Power Off.5. Wait for computer to shut down completely.6. Turn the MAIN POWER switch to OFF.

OFF is green.7. Make sure floor and surfaces are clear of objects, tools, and

chips.

Don't remove the part yetAs long as you keep your part inside the vise, you will be able to continue machining at any point.

+ When you’re finished, inspect the part and check tolerances. + If another user needs the machine and you have more operations to complete, remove the vise and keep it

at your desk. + When returning to the machine, ensure the G54 Work Coordinate System coordinates are the same as

before.

DO NOT USE COMPRESSED AIR TO CLEAN THE INSIDE OF THE MILL.

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PREPARATION1. Cut and measure stock first.2. Ensure stock, part, and workholding are

accurate in your CAM software.3. Check that Work Home is on the top center

of the receiver plate.4. Make sure there are no errors in CAMplete.

Ask shop staff for help if needed.

USING THE MILL1. Verify file. (page 8)2. Start up the mill. (page 9)3. Install work in vise. (page 12)4. Check Work Coordinate System. (page 12)5. Set the Tool Length Offsets. (page 13)6. Load the program. (page 14)7. Run the program. (page 15)

CLEANUP1. Run the Goodnight Program.2. Clear chips from inside machine.3. Clear chips from bins behind machine.4. Close the doors.5. Turn off the mill.6. Clean tables and the floor.7. Put away all tools.

HANDS ON

RECAP.

DO NOT USE COMPRESSED AIR TO CLEAN MACHINE.

ALWAYS RUN IN 10% RAPID & USE SINGLE BLOCK TO CONFIRM TOOL OFFSET.

TAKE ALL CAMPLETE ERRORS SERIOUSLY.