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Tool Tutorial

CNC Metal Mill (Tormach)

(LinkThe Tormach can cut a diverse range of materials from aluminum to PDFplastics such as ABS, PVC and Delrin.

A mill is used to machine surfaces, cut slots and pockets, and drill holes to precise dimensions. In the case of the Tormach mill, the spindle holds the tool and moves in the Z axis, while a clamp on the table holds your work and moves the X and Y axes.

A CNC mill is controlled by a program created by CAM software such as Fusion 360, VCarve Pro, Cut3D or InventorCAM.

This tool can deliver enough force to break brittle tools, crush bones, and tear flesh.

Electronic devices within the electrical cabinet may retain dangerous levels of electrical charge even after power has been turned off.

Tool Anatomy

Power Switch - Key switch turns the machine on and off
Emergency Stop - Reserved for emergencies. To deactivate and reset, you must twist the spring-loaded knob.
Maintenance Tag - Manually tracks the usability status with Green/Yellow/Red cards

Tool Safety

Safety Checklist

    Never leave the machine unattended while it is running
    Power off the spindle before changing tooling
    Ensure that your clothing and PPE is safe for operation

    Personal Protective Equipment

    At the Tormach, Well-fitted Clothes, Closed-toed Shoes, and Safety Goggles are required. Hearing protection is recommended. 

    Loose sleeves must be rolled up and long hair and scarves must be tied back. Avoid any dangling drawstrings or other articles of clothing that may come in contact with the mill.

    Tool Care

      Take small cuts at slow speeds.
      Be prepared to stop the machine at any time using the e-stop.
      Submit a maintenance request when needed.

      Tool Operation

        Locate the edge of your piece and Zero the x/y origin
        Insert the cutting tool
        Locate the top of your work piece and zero the Z-axis
        Set the spindle speed
        Place the shield on the front of the machine
        Start the spindle
        Start the coolant
        Begin your cut by double-clicking Cycle Start
        Monitor your piece until the program is complete
        Cleanup

        Inspection

        Before you start using the mill you are expected to do an initial inspection of the mill and access its readiness for use. Consult the checklist at the end of this document as well as the detailed processes here.

        Troubleshooting

        Extensive troubleshooting information is available in section 9.6 of the manual, on page 156 of the PDF.

        Cleanup

          Deactivate the drive motors by pushing the e-stop
          Exit Mach3
          Delete any files copied to the computer
          Remove your usb/flash drives, and shut down the computer
          Power off the full unit
          Vacuum and sweep any chips and debris
          Wipe any excess coolant with a rag
          Return any vice, hold-downs, or cutting tools to their home
          Note any maintenance needs or concerns on the tag and at protohaven.org/maintenance
          Recycle waste in the scrap bins

          Scrap Breakdown

          Maintaining these is a shared, communal responsibility. This is where we can acknowledge exactly where the tool-related scrap bins may be located in the shop. The following is our general approach to scrap hygiene:

            When you notice the scrap bins are full, it’s time to take it to the dumpster out back. Feel free to enlist a helping hand. If you notice valuable material while emptying the bins, use your judgement to selectively save a few pieces or take it home for your personal use.

            Special Setups

            Rotary Tool

            Tutorial)
            INDEX MACHINING

            This is where you machine an entire face as if it was a single part, then manually use g-code to rotate the stock and start a second cut file that cuts the second face. Cut 3D and VCarve Pro are sufficient to achieve this type of machining.

            4 AXIS MACHINING

            This is complex machining where the 4th axis is rotating while a cutting tool is removing material. To generate g-code for this type of machining you will need a more advanced CAD program like InventorCAM, SprutCAM or RhinoCAM.

            Advanced Workholding

            Additional Resources

              The Tormach document library
              CNC Concepts - Has lots of good training materials for beginner and advanced users
              Modern Machine Shop Online - Has lots of news about the machining industry