CNC Machining
Modern CNC machines are capable of micron-scale (0.001+ mm) material processing. Typical accuracy and repeatability are under 10um (linear) and under 0.01 degrees (angular).
Setup
The ideal machine space is a climate-controlled room (temperature, humidity, airflow) with a flat, level, finished floor (ex. thick polished reinforced concrete).
We recommend a solid-state 3-phase converter (240VAC 1P to 240VAC 3P) that is rated for at least twice the rated power of the machine as marked on its nameplate (ex. 10kVA machine, 25kVA converter). This safety factor is important for burst power stability (ex. spindle ramp-up) and burst regeneration tolerance (ex. spindle braking).
We recommend a step-down transformer (240VAC 3P to 220VAC 3P, delta-wye) that supports at least the rated power of the machine (ex. 10kVA machine, 10kVA transformer or better).
Tooling
For tapping, we use NT Tool Synchrofit 2 (elastic tapholders) with dual-contact BT30 (NT Tool, AHO type).
| Function | Toolholder (NT Tool) | Collet (NT Tool) | Tap Interface Standard |
|---|---|---|---|
| M2 | WBT-AHO30A-SMH8-75 | ER8-3.0A | DIN371 |
| M2.5 | WBT-AHO30A-SMH8-75 | ER8-3.0A | DIN371 |
| M3 | WBT-AHO30A-SMH8-75 | ER8-3.5A | DIN371 |
| M4 | WBT-AHO30A-SMH16-90 | ER16GH-4.5-3.4 | DIN371 |
| M5 | WBT-AHO30A-SMH16-90 | ER16GH-6-4.9 | DIN371 |
| M6 | WBT-AHO30A-SMH16-90 | ER16GH-6-4.9 | DIN371 |
| M8 | WBT-AHO30A-SMH16-90 | ER16GH-8-6.3 | DIN371 |
| M10 | WBT-AHO30A-SMH16-90 | ER16GH-7-5.5 | DIN376 |
| M12 | WBT-AHO30A-SMH16-90 | ER16GH-9-7.1 | DIN376 |
Operation
The automatic tool change command (ex. M06 T88) selects a tool number (88) in the tool library, checks whether that tool is installed in the ATC carousel according to the ATC list (ex. tool 88 in ATC slot 10), then, if installed, performs an ATC cycle to that ATC slot (10).
Setting new tools on the ATC list can only be done in MDI mode, for accidental change prevention.
The manual-pulse-generator pendant axis-selection knob must be set to OFF in order to move the machine-head (else "Handle Mode" alarm).
Workpiece clamping force deforms the part while held. Accurately machined dimensions may not survive when the part is released. Minimize clamping force while maintaining sufficient workpiece retention. Plan fabrication around clamp-release deflection.
Overview
Dimensional Standard: Metric
Machine: Brother Speedio M200X3 (5-axis VMC with turning-capable rotary table)
| Spec | Description |
|---|---|
| Main Spindle RPM | 16K |
| Turning Spindle RPM | 2K |
| Travel (XYZ position, A tilt, C turn) | 200x440x305, 120 ~ -30, 360+ |
| Simultaneous Axes | 4 (XYZ + A/C) |
| Positioning Accuracy | 6~20um |
| Linear Repeatability | under 6um |
| Angular Repeatability | under 0.005 degrees |
| Nominal Power Input | 10kVA (200-230VAC 3P+GND) |
| Nominal Air Input | 0.5MPa 165L/min (SMC, KK130 connector) |
Add-Ons (most are default on NA product package):
- 16k rpm spindle with dual-contact BT30 spindle-toolholder interface
- 22-slot automatic tool-changer (1.4s chip-chip) (0.8s tool-tool)
- top cover
- PLC
- A-axis clamp (turning axis) and C-axis clamp (4th axis)
- chip shower and 150L coolant tank with chute
- automatic grease lubricator
- Coolant-Thru-Spindle Interface (CTSI) (WARNING: requires 1.5MPa)
- hydraulic interface
CAD-CAM Workflow
| Step | Tool |
|---|---|
| General Design | Regular Documents |
| CAD | Autodesk Inventor |
| CAM | Autodesk Inventor CAM |
Toolholders
Assorted
We generally prefer dual-contact hydraulic toolholders with short gage lengths (ex. 45mm) and direct tool mounting (no collets) for best rigidity and runout.
- Standard hydro holders for light milling, drilling, and finishing.
- Slim hydro holders for tighter spaces.
- Strong hydro holders for roughing.
| Use | MFG | Product Family | Ordering ID | Description (mm) |
|---|---|---|---|---|
| 6D | Big Daishowa | Slim Hydro | BBT30-HDC6S-60 | dual-contact, 60 gage |
| 6D | Maritool | Standard Hydro | BT30-HC6-2.25D | dual-contact, 60 gage |
| 6D | Big Daishowa | Standard Hydro | BBT30-HDC6-45 | dual-contact, 45 gage |
| 8D | Big Daishowa | Standard Hydro | BBT30-HDC8-45 | dual-contact, 45 gage |
| 10D | Big Daishowa | Standard Hydro | BBT30-HDC10-45 | dual-contact, 45 gage |
| 12D | Big Daishowa | Standard Hydro | BBT30-HDC12-45 | dual-contact, 45 gage |
| 12D Strong | YG1 | Power E Hydro | CBT30-HC12P-69 | strong hydro, torque withstand 110Nm |
| 20D Strong | YG1 | Power E Hydro | CBT30-HC20P-90 | strong hydro, torque withstand 520Nm |
| External/Facing (20 square vertical) | NT Tool | Turning Tools for Brother Speedio | 2120 12020098 | BT30, Right-Hand, 98 Gage, 20x20x50 Toolslot |
| Facing (20 square horizontal) | NT Tool | Turning Tools for Brother Speedio | 2120 11020081 | BT30, Right-Hand, 81 Gage, 20x20x58 Toolslot |
| Boring Bar (10 round vertical) | NT Tool | Turning Tools for Brother Speedio | 2120 00010038 | BT30, 38 Gage, 10 DIA x 40 DP Toolslot |
https://www.bigdaishowa.com/en/products/tool-holders/hydraulic-tool-holders
https://en.nttool.com/products/pid/158/
Tools
Endmill
YG1
| Series | Spec (DIA/DOC/LG) | Use | Ordering ID |
|---|---|---|---|
| ALUPOWER | 12x24x83x0.5R | ALU | 4XNEM12005RET |
WIDIA
| Series | Spec (DIA/DOC/LG) | Use | Ordering ID |
|---|---|---|---|
| Varimill Extreme | 12x24x83x0.5R | PMKSH | 4XNEM12005RET |
| Varimill 1 | BALL 6x10x57 | PMKSH | 47N006002T |
Drill
WIDIA, Varidrill 3xD (PMKNS) (solid carbide, coated, grade WU25PD)
https://www.widia.com/ca/en/products/holemaking/solid-carbide-drills/varidrill.html
| Drill DIA (mm) | Hole Purpose | Shank DIA (mm) | Ordering ID |
|---|---|---|---|
| 1.984 | 2D PREP | 4h6 | VDS201A01984 |
| 2.1 | M2 SCREW | 4h6 | VDS201A02100 |
| 2.5 | M3 TAP DRILL | 4h6 | VDS201A02500 |
| 2.947 | 3D PREP | 4h6 | VDS201A02947 |
YG1, Dream Drill Alu 5xD (solid carbide with coolant-thru)
| Drill DIA (mm) | Hole Purpose | Shank DIA (mm) | Ordering ID |
|---|---|---|---|
| 3.1 | M3 SCREW | 6h6 | DGE433031 |
| 3.3 | M4 TAP DRILL | 6h6 | DGE433033 |
| 3.9 | 4D PREP | 6h6 | DGE433039 |
| 4.1 | M4 SCREW | 6h6 | DGE433041 |
| 5 | M6 TAP DRILL | 6h6 | DGE433050 |
| 5.9 | 6D PREP | 6h6 | DGE433059 |
| 6.1 | M6 SCREW | 8h6 | DGE433061 |
Reamer
WIDIA High-Speed Reamers for Blind Holes (solid carbide)
https://www.widia.com/ca/en/products/holemaking/reaming-tools/hsr--high-speed-reamers--carbide.html
Grade K10F: uncoated fine-grain carbide (supports PMKNS, but best for non-ferrous reaming)
| Hole DIA/TOL (mm) | Shank DIA (mm) | Ordering ID |
|---|---|---|
| 2H7 | 3 | 2446025 |
| 3H7 | 3 | 2446029 |
| 4H7 | 4 | 2446031 |
| 5H7 | 6 | 2437472 |
| 6H7 | 6 | 2437523 |
| 8H7 | 8 | 2437525 |
| 10H7 | 10 | 2437526 |
| 12H7 | 12 | 2437527 |
Taps
| Video | Link |
|---|---|
| Tapping Basics | https://www.youtube.com/watch?v=bkrUzGooA9k |
| YG1 Prime Tap Intro | https://www.youtube.com/watch?v=p6AU1jIXxmw |
YG1, PRIME TAP (COATED HSS, PMKN) (2022 CATALOG PG321)
TRE30 (SPIRAL FLUTE, COARSE THREAD, BLIND HOLE 2.5xD, CHAMFER DIN2197-C)
TRJ15 (SPIRAL POINT, COARSE THREAD, THRU HOLE 3xD, CHAMFER DIN2197-B)
| Thread | Tap Standard | Ordering ID |
|---|---|---|
| M2 | DIN371 | TRE30136GS |
| M2 | DIN371 | TRJ15136GS |
| M2.5 | DIN371 | TRE30176GS |
| M3 | DIN371 | TRE30206GS |
| M3 | DIN371 | TRJ15206GS |
| M4 | DIN371 | TRE30246GS |
| M4 | DIN371 | TRJ15246GS |
| M5 | DIN371 | TRE30286GS |
| M6 | DIN371 | TRE30316GS |
| M6 | DIN371 | TRJ15316GS |
| M8 | DIN371 | TRE30366GS |
| M8 | DIN371 | TRJ15366GS |
| M10 | DIN371 | TRE30426GS |
| M10 | DIN371 | TRJ15426GS |
| M12 | DIN376 | TRE30506GS |
| M12 | DIN376 | TRJ15506GS |
Chamfering
Chamfering: Carmex, (carbide grade MT8) (PMKNSH)
Carmex, Mini Chamfer
Carmex, Multi-Function Tools
8mm cutter DIA is ideal for small parts because holes are typically for M6 and under (for efficient Z plunge chamfering).
| Type | Use (hole DIA, material grade) | Description (Internal DEG x Cutter DIA x Max Radial Cut x Tool Length x Shank DIA) | Ordering ID |
|---|---|---|---|
| Multi-Function | CHAMFER PMKNSH | 90x8x4x73x10 | MF 1008 L16 A90 CR3 |
| Multi-Function | SPOT PMKNSH | MF 0605 L10 A120 CR3 | |
| Multi-Function | ENGRAVE PMKNSH | MF 0605 L10 A60 CR3 | |
| Mini Chamfer | 2+ PMKNSH | 90x1.5x0.3x39x3 | MC 03015 C3 A90 MT8 |
| Mini Chamfer | 2+ KNS | 90x1.5x0.3x39x3 | MC 03015 C3 A90 K20 |
| Mini Chamfer | 3+ PMKNSH | 90x2.5x0.5x39x3 | MC 03025 C6 A90 MT8 |
| Mini Chamfer | 3+ KNS | 90x2.5x0.5x39x3 | MC 03025 C6 A90 K20 |
Turning
Other
Facemill
Single Point Diamond Tools
Workholding
We use Schunk KSC3 self-centering vises for their high clamping force (35kN) (workpiece pre-stamping is not required), fully encapsulated spindle, and 10um repeatability.
Compared to the previous gen (KSC):
- better anti-corrosion (nickel-plated body)
- better mounting flexibility (Lang 96x96 M10 compatible)
- more compact form-factor (driving hex does not stick out)
| Function | Description | Schunk Product ID |
|---|---|---|
| Vise with Reversible Jaws | KSC3 grip 125-160 | 1514238 |
| Vise | KSC3 125-160 | 1514241 |
| Mounting Pin | SPA-40RF (between vise and quick-plate) | 0432369 |
| Indexing Pin | IXB-V1 (between vise and quick-plate) | 0432371 |
| Quick Plate | NSE3-138-V1 | 1313723 |
| Adapter Plate | (between quick-plate and machine-table) | custom |
| 5-axis System Jaw | compact, not reversible, requires top jaws, 1-piece | 432472 |
| Ground Top Jaw | simple flat, 1-piece | 1373278 |
| Prismatic Top Jaw | for round workpieces, 1-piece | 1373344 |
These vises support a clamping range of 0 to 156mm/163mm (with the default reversible jaws) but they only have a ~40mm actuation range; the system jaws must be reversed and/or remounted (to either the inner or outer position). For max ranges of different system jaws, see the KSC3 info sheet, page 24 (default reversible jaw is 10).
For best efficiency building prototype parts, use multiple vises because it's faster and more reliable to quick-swap the vise than the jaws.
| Name | Function | Description |
|---|---|---|
| Vise1 | 0 - 40mm (up to 1.5") | reversible jaws, inner |
| Vise2 | 38 - 78mm (2" to 3") | reversible jaws, outer |
| Vise3 | 85 - 125mm (3" to 4") | reversible jaws, inner, reversed |
| Vise4 | 123 - 163mm (5" to 6") | reversible jaws, outer, reversed |
| Vise5 | 0 - 40mm (up to 1.5") | 5-axis jaws with ground top jaws, inner |
| Vise6 | 38 - 78mm (2" to 3") | 5-axis jaws with ground top jaws, outer |
- driving interface: 12mm male hex (use socket)
- driving max torque: 100 Nm
- jaw screw head: M10 female hex
- jaw screw target torque: 60 Nm
Supporting Tools
BT30 tool handling: Maritool, 30-Taper-Lock
Coolant: LubeCorp, GreenCut Cutting Fluid
Power Supply
Utility (240VAC 1P) -> Main Breaker Panel -> Solid-State Phase Converter (240VAC 3P) -> Fusible Disconnect -> Delta-Wye Step-Down Transformer (220VAC 3P) -> 3-Phase Electrical Outlet
Dedicated Phase Converter: Phase Technologies, PTE010RQT-H3S1 (Phase Perfect Enterprise, 10HP, NEMA 3R, Quiet, On/Off Switch, Protec Surge Protection, 30kg) (input 1-phase 240VAC, output 3-phase 240VAC with max steady-state 36A and class 10 thermal-overload motor-starting)
Fusible Disconnect (pre-transformer): Schneider Electric, CH362AWK (60A/600V/3P, NEMA 3R/12, CSA) (with fuses, Mersen AJT30; fuse-reducers, Mersen J636)
Dedicated Step-Down Transformer: 3-phase 240VAC to 3-phase 220VAC, isolation, 10kVA
Receptacle/Plug (NEMA15-50, post-transformer): Hubbell, HBL8450A/HBL8451C (CSA/UL)
Air Supply
Dedicated Air Compressors: Makita, MAC320Q (4 parallel units) (each rated 50% duty cycle per hour)