Mach3 Workflow
Establish the Origin
Mach3 doesn't have any knowledge of what's actually going on with the CNC machine. It just sends commands to the machine and hopes they are received and executed properly. Thusly, you need to set the machine up so everything is where Mach3 expects it to be. In this section we'll be establishing the origin of the part.
1. Make sure you've installed the router bit you will use to cut the part
a. To unfasten your bit: right hand wrench on top bolt (left hand wrench on lower) push wrenches away/outward from each other
b. To fasten your bit: ight hand wrench on top bolt (left hand wrench on lower) push wrenches together/towards each other
2. Jog the gantry until the router bit is roughly in the lower left hand corner of the stock
3. Press the tab key on the keyboard to expose the jogging control fly-out.
4. Click the 'Jog Mode' button until the yellow box is highlighted above 'Step'.
5. Clock the 'Cycle Jog Step' button until it reads '0.010'
6. Press the 'Page Down' button on the keyboard to lower the router until the bit is just barely touching the top of the stock.
7. Press tab key to exit the jogging control fly-out.
8. Click the blue 'Zero x', 'Zero y' and 'Zero z' buttons in the lower left gray info readout. (Do not click the button labeled 'ref x', 'ref y', 'ref z' or 'goto zero'). Verify that the x, y, and z axes all read 0 in the display. You have now set the 0,0,0 origin of your working space for the router.
Air Test
Now that you've established the x,y,z origin at (0,0,0) it's time to run a simulation of your program. You must run a full simulation of the program prior to cutting. This is essential to make sure your gcode is correct and to catch any potential errors or dangerous situations.
1. Change to the 'MDI/Settings' window
2. In the MDI box (next to the big blue button labeled "MDI") enter the following command: g01 z1
a. this will move the router head exactly 1 inch up from the origin.
3. Zero the z-axis again. Click on the gray "Zero Z" button in your current screen. -- VERY IMPORTANT! If you don't re-zero in the air, the machine will crash into your stock during the air test.
4. Change to the 'Program Run' window
5. Double check everything - the router's coordinates should read (0,0,0), but actually be 1 inch above the stock.
6. The router should not be turned on - this is only a test, so we won't be cutting anything
7. Get in a position where it will be easy to press the E-Stop button (the RED push button on the gray box on the router)
8. Press the 'Run' button on screen to start executing your part program
9. Carefully watch the program execute in it's entirety. Things to watch out for:
- The router router does not move to some strange z-height
- The router bit stays inside the boundaries of the stock the entire time
- The router bit does not pass over any screws or clamps
- The router bit properly moves to the clearing plane before jogging to another area to plunge
- The router doesn't plunge unusually deep
Air Test with Multiple Bits
If you are using more than one router bit for your program you'll need to reset z-axis every time you change a bit, both in the air test and and the actual machine operation itself.
1. Change to the 'MDI/Settings' window
2. In the MDI box (next to the big blue button labeled "MDI") enter the following command: g01 z1
a. this will move the router head exactly 1 inch up from the origin.
3. Zero the z-axis again. Click on the gray "Zero Z" button in your current screen. -- VERY IMPORTANT! If you don't re-zero in the air, the machine will crash into your stock during the air test.
4. Change to the 'Program Run' window
5. Double check everything - the router's coordinates should read (0,0,0), but actually be 1 inch above the stock.
6. The router should not be turned on - this is only a test, so we won't be cutting anything
7. Get in a position where it will be easy to press the E-Stop button (the RED push button on the gray box on the router)
8. Press the 'Run' button on screen to start executing your part program
9. Carefully watch the program as outlined above.
10. When your program stops (this happens when it comes to a T code which signals to change the tool) use the jog tool to move the router up and to a location where you can change the bit.
11. Move the bit to the actual z-axis location at the top of your stock.
12. Click the blue 'Zero x' button in the lower left gray info readout. (Do not click the button labeled 'ref z' or 'goto zero').
13. Change to the 'MDI/Settings' window
14. IMPORTANT: In the MDI box (next to the big blue button labeled "MDI") enter the following command: g01 z1
a. this will move the new bit exactly 1 inch up from the origin to continue the air test.
15. Change to the 'Program Run' window
16. Press the 'Run' button on screen to resume executing your program.
17. Carefully watch the program as outlined above.
Part Placement
If you are curious about your toolpath size and locations in relation to your work piece, check your dimensions by moving the router to the lower left and upper right corner of the piece. Only do this while the router is in the air cut position, so as not to drag the bit across your work piece.
- Click on the ToolPath button at the top of the screen. On the upper right of the toolpath window you should see a 'Program Limits' display, showing X Range, Y Range, and Z Range. There is also a nice image of the toolpath in the window below that.
- For instance, my part reads
X Range: -0.0009, +5.7487
Y Range: -0.0003, +2.7494
Z Range: -0.7500, +0.125
- Using GCODE commands in the MDI/Settings window, you can move the router to that upper left corner (MAX X, Y, and Z) of your part and check it is on your work piece.
For the part above, in the MDI textbox in the MDI/Settings window I would type: G01 X5.75 Y2.75 Z0
this moves the router at the current feedrate (G01) to the coordinates X5.75 Y2.75 Z0.
- If the placement looks good, return the machine to the part origin: G01 X0 Y0 Z0
- If the placement does not look good, you need to move your work piece or re-set the xyz origin.
- NOTE: it is only wise to move your machine to a Z0 coordinate when it is set up for an air test (e.g. the home is offset upwards off of the table as described in the Air Test section above), otherwise you will drag the bit across your work piece ruining both!
Cut the Part
Since everything went splendidly during the air test, we're ready for the real thing!
Return the virtual Z-height to a physical zero
We moved our entire coordinate system upwards 1 inch before we ran our air test. We now need to tweak the z coordinates to return the virtual z zero to the physical z zero.
1. Switch to the 'MDI/Settings' window.
2. In the MDI box (next to the big blue button labeled "MDI") enter the following command: g01 z0. This will return the router bit to it's virtual z-height of 0 inches (which is physically 1 inch above your stock).
3. With the mouse, set focus to the z-coordinate DRO (Digital Read Out) box
4. Type '1.000' in the z-coordinate DRO and press 'Enter'.
Run the Real Thing
1. Change to the 'Program Run' window
2. Double check everything - make sure the stock is secure, the router collet is tightened
3. Turn on the overhead dust collector
4. Plug in the router
5. Turn the router on
6. Get in a position where it will be easy to press the E-Stop button
7. Press the 'Run' button to start executing your part program
8. Use the shop vacuum to suck up dust and chips local to the router
9. Carefully watch as the program executes in its entirety
Run the Real Thing with Multiple Bits
1. Change to the 'Program Run' window
2. Double check everything - make sure the stock is secure, the router collet is tightened
3. Turn on the overhead dust collector
4. Plug in the router
5. Turn the router on
6. Get in a position where it will be easy to press the E-Stop button
7. Press the 'Run' button to start executing your part program
8. Use the shop vacuum to suck up dust and chips local to the router
9. Carefully watch as the program executes in its entirety
10. When your program stops (this happens when it comes to a T code which signals to change the tool) use the jog tool to move the router up and to a location where you can change the bit.
11. Turn the router off
12. Unplug the router
13. Move the bit to the actual z-axis location at the top of your stock.
14. Click the blue 'Zero x' button in the lower left gray info readout. (Do not click the button labeled 'ref z' or 'goto zero').
15. Jog the router up in the z axis
16. Plug the router back in
17. Turn the router on
18. Press the 'Run' button on screen to resume executing your program.
19. Carefully watch the program as outlined above.