Shenzhen Alu Rapid Prototype Precision Co., Ltd.

Follow these guidelines:

1.Personal Protective Equipment (PPE): Wear ANSI-approved safety glasses, hearing protection (essential for metal cutting noise), a dust mask or respirator for fumes/chips, closed-toe shoes, short sleeves or tucked-in shirts, and remove jewelry/hair ties to avoid snags.

2.Shop Practices: Keep the workspace clear of debris, never run machines unattended, use emergency stops (E-stop) readily, and avoid operating under the influence of substances. For metal, use cutting fluid to reduce fire risks from hot chips.

3.Machine-Specific: Ensure guards are in place, verify coolant levels to prevent overheating, and start new programs at reduced speeds (e.g., 20% rapid override) to avoid crashes.

4.Behavioral Rules: Communicate with others, clean spills immediately, and report hazards.

Step 2: Prepare Materials, Tools, and Machine

1.Select the Metal and Machine: Choose metal based on strength, environment (e.g., corrosion-resistant aluminum for outdoors), and tolerances. For beginners, start with softer metals like aluminum. Pick a suitable machine: mills for complex 3D shapes, lathes for cylindrical parts.

2.Tools and Accessories: Use carbide end mills or inserts rated for metal (e.g., coated for durability). Calculate speeds/feeds: RPM = (Surface Feet per Minute × 3.82) / Tool Diameter; Feed Rate = RPM × Chips per Tooth × Number of Flutes. For aluminum, aim for 800–2000 SFM and 0.002–0.005 inches per tooth.

3.Machine Warm-Up: Power on, release E-stop, and run a warm-up cycle (e.g., spindle at low RPM for 10–15 minutes) to stabilize temperature and lubricate. Check oil/coolant levels and clear the table with compressed air.

4.Design the Part: Use CAD software (e.g., Fusion 360) to create a 2D/3D model, accounting for tool radii (fillet sharp corners) and tolerances (e.g., ±0.001 inches for precision fits).

Step 3: Set Up the Machine

Setup ensures accuracy—poor setup causes crashes or scrap parts.

1.Install Tools: Power off, insert tools into the spindle or carousel (e.g., below V-flange, secure with retention knobs). Set tool length offsets (TLO) using a touch probe or 1-2-3 block: Jog to reference, measure, and input (e.g., H1 for Tool 1).

2.Secure the Workpiece: Use vises (align with dial indicator for <0.001" parallelism), clamps, or T-slots. For metal, add parallels for grip and leave extra stock for facing. Avoid over-extension on lathes to prevent vibration.

3.Set Work Coordinates (Offsets): Home axes, then use an edge finder for X/Y zero (subtract tool radius). For Z, touch off the part top with a shim or indicator. Input into G54–G59 offsets.

4.Load Coolant and Program: Direct nozzles at the cut zone for chip evacuation. Transfer G-code via USB.

Step 4: Program the Machine

Programming converts your design into machine instructions using CAM software.

Step 5: Run the Machine

1.Test Run: Start in single-block mode with overrides (20–50% speed). Monitor for unusual noises/vibrations—stop and adjust feeds if chips are powdery (too fast) or stringy (too slow).

2.Full Operation: Clear area, close doors, press Cycle Start. Stay nearby with hand on Feed Hold/E-stop. For metal, watch coolant flow to avoid dry cuts that dull tools.

3.Monitoring: Observe chip formation (blue chips indicate overheating) and measure interim dimensions with calipers.

Step 6: Post-Processing and Maintenance