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MachPro Lathe Operating Manual

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Introduction

This manual gives the process for basic operation of a using the MachPro Lathe control. The screen is shown below, followed by a brief summary of the different features of the screen. The number shown in the screenshot refers to a brief description below the image. 

To open the control software double-click on the profile icon on the desktop.

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Lathe Canned Cycles

Pull down the Wizard menu and click Select Wizard

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All of the features and use of the Lathe Canned Cycles are discussed in this YouTube video series. These videos are for an older version of Mach. MachLabs has continued to improve the canned cycle code, and the interface remains the same as the videos show. 

Lathe Canned Cycle video series

Control Screen Overview:

GCode Page

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  1. Status
    • Status - Displays any current messages (Home All Pressed, Cycle Start Pressed, etc.)
    • State - Displays the current state of the machine (Run, Feedhold, etc)
    • Cycle Time - Displays how long the GCode has been running
    • Date - Date and time of the timezone of the control
  2. Tool Path
    • Regen ToolPath - Refresh the toolpath of the GCode
    • View Top - Top view of the part
    • View ISO - Side view of the part
  3. File
    • Recent - Load a recently loaded GCode program
    • Load - Load a program from the computer or flash drive
    • Edit - Edit the code that is loaded into the software
    • Close - Close the GCode that is currently loaded in the software
  4. Control
    • Cycle Start - Starts the gcode from from the beginning of the part
    • Feed Hold - Pauses the gcode program and keeps the spindle running
    • Cycle Stop - Stops the gcode program from running
    • Reset - Resets the alarm and also enables the machine
    • Disable - Disables the control for software configuration changes
  5. Tool Path Display
    • Show the X and Y path that the machine will follow when running the GCode program
    • Zoom – Right click with the mouse and move mouse up/down or using the scroll wheel on the mouse
    • Rotate – Left click with the mouse and rotate the part by moving the mouse
    • Pan – Press and hold [Ctrl] on the keyboard and left click with the mouse, then pan by moving the mouse (one-hand control option is to use left and right mouse click and move the mouse. No [Ctrl] press needed)
  6. GCode Display
    • Part Counter
    • GCode Line
    • GCode Display
  7. Advanced - Expand or Collapse
    • Single Block - If active the software will go line by line through the GCode when you press the cycle start button
    • Block Delete - Deletes the block of GCode that is selected
    • Part Counter - Displays the number of parts that the machine has produced
    • M1 OPT Stop - If active the software will stop at any M1 commands in the GCode program and waits for cycle start
    • Alexsys - Opens up the conversational assistant Alexsys in another window (if installed)
    • Dry Run - If active the software will ignore all mist or flood commands
    • M-S-T Lock - If active the software will ignore all Macro codes, Spindle codes and Tool commands
    • Collapse v - If selected this will minimize the Advanced buttons
  8. Position Display
    • Axis Positions - Large DROs
    • Distance To Go - Yellow DROs
    • Configurable Gauge - Axis Load or Velocity
  9. Position Display Dashboard
    • MDI - Opens up a window that allows for GCode commands
    • Viewing Part - Shows the part coordinates or machine coordinates of the machine
    • 5 Configurable Function Buttons
  10. Active Modals
    • Active Offset - Shows the current active fixture offset (G54, G55, etc)
  11. Tool Display
    • T - The current – the first two digits refer to the tool and the second two refer to the offset
    • Picture – shows the current tip direction of the tool
    • Tool Post – shows which tool post the tool is connected to – Primary, Secondary or not defined
    • Description of the current tool
  12. Feedrate Display
    • F - The current feedrate commanded
    • Feed OV - The current Feedrate Override utilizing the Feedrate Override knob on the operating panel (0-200%)
    • Rapid OV - The current Rapid Override utilizing the Rapid Override knob on the operating panel (0-200%)
  13. Spindle Display
    • S - The current spindle speed
    • Rpm - The current spindle speed feedback
    • FWD - Turns on if the spindle is moving Forward
    • REV - Turns on if the spindle is moving in Reverse
    • Spindle OV - The current spindle override (0-200%)
    • Spindle Load - The current spindle load utilizing the spindle speed feedback
    • Range - Displays the current spindle range (spindle pulley) 
    • G50 Speed Limit - Displays the current G50 limit and changes to yellow when a limit is active
  14. Dashboard
    • Configurable Dashboard
    • Add Widgets

Tools Page

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  1. Edit
    • Edit Offsets - No offset changes can be made unless this button is yellow. It also displays the zero buttons near the DROs to the right. 
  2. Tools
    • Tool Table - View and edit tool table 

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  3. Control
    • Cycle Start - Starts the gcode from from the beginning of the part
    • Feed Hold - Pauses the gcode program and keeps the spindle running
    • Cycle Stop - Stops the gcode program from running
    • Reset - Resets the alarm and also enables the machine
    • Disable - Disables the control for software configuration changes
  4. X and Z Calibration
    • Teach - Touch tool off on part and press teach
    • Measured DRO - Enter Diameter /  Position of the part where the Teach was pressed
    • Update - Calculate the new value for the tool offset and store it to the tool table
  5. X and Z Correction
    • Correction DRO - Enter the amount you want to adjust the tool offset
    • Update - Calculate the new value for the tool offset and store it to the tool table
  6. Tool Offsets
    • Displays all the values for the current tool
    • Update - Calculate the new value for the tool offset and store it to the tool table
  7. Jump to Tool Number or Tool Pocket
    • 1,2,3,4 etc. -  Tool number (Tool change). Just press the button and the tool will change. 

Fixtures Page

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  1. Edit
    • Edit Offsets - View and edit fixture offsets
  2. Fixtures
    • Fixtures Table - View and edit fixture table (G54, G55, G56, etc.)
  3. Control
    • Cycle Start - Starts the gcode from from the beginning of the part
    • Feed Hold - Pauses the gcode program and keeps the spindle running
    • Cycle Stop - Stops the gcode program from running
    • Reset - Resets the alarm and also enables the machine
    • Disable - Disables the control for software configuration changes
  4. Current Fixture Offsets
  5. Current Work Shift Offsets
  6. Current G52 Offsets


Service Page

Maintenance

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  1. Limits
    • Soft Limits - Toggles software limits on or off
    • Limit Override - Toggles to allow for the machine to move off a limit switch
  2. PLC
    • Reset Pocket - Only used for tool changers. 
    • PLC Sequence - 
  3. Control
    • Cycle Start - Starts the gcode from from the beginning of the part
    • Feed Hold - Pauses the gcode program and keeps the spindle running
    • Cycle Stop - Stops the gcode program from running
    • Reset - Resets the alarm and also enables the machine
    • Disable - Disables the control for software configuration changes
  4. Settings
    • Interface Config - Opens the User Interface configuration screen
    • Motion Controller - Opens the plugin for the Motion Controller
    • Screen Config - Edit the screen layout
    • Industrial Theme - Applys Industrial Theme
    • Toggle Menu - Turns the top menu on or off 
    • Compile Scripts - Refreshes (recompiles) programming scripts
  5. System Information
  6. Support
    • Remote Support - Starts a TeamViewer session
    • Online Support - Opens up the web page with the support options
    • Online Manuals - Opens the MachGroup documentation site
    • History - Views status history and alarms
  7.  Homing
    • Home X - Homes the X axis
    • Home Z - Homes the Z axis
    • Home All - Homes all axes
  8. User
    • Logout - Logs out of the Windows username
    • Power - Turns off the computer
Dashboard

The Dashboard is used to make the control just the way you want it! For more information, see this link: Configure Dashboards . 


Machine I/O

This page is used for diagnostics and shows all your machine IO. 

Homing

To home the Machine, begin by click the [Reset] button and then the [Service] tab and click on [Home All].

Programmed Movement

MDI

To command a movement using the MDI feature, press the [MDI] button.

Enter the desired G-Code command into the field and press [Cycle Start] to execute the command(s). The up/down arrow buttons will scroll through the history of cycled commands. Click the Red [X] to close the MDI window.

Example MDI Command

G-Code

The primary method of commanding motion is using G-Code files. G-Code files can be hand written, generated by a wizard, or generated from CAD files using a CAM program.

Spindle Control

G-Code Spindle Control

The spindle is controlled through G-Code using the M-Codes M3 (Clockwise), M4 (Counterclockwise), and M5 (Off). To control the spindle speed in RPMs an S word is added.

For example, M3 S2000 would turn the spindle on in the clockwise direction at 2000 RPM.

Manual Spindle Control

To control the spindle separately from G-Code use the Spindle Forward / Spindle Stop button below the DRO.

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Spindle Display

The current spindle settings are shown in the main Spindle Display.

  1. S – Commanded Speed
  2. Spindle OV – Spindle Override Percentage
  3. Spindle Load – % of the load of the spindle
  4. G50 Speed Limit - Displays the current G50 limit and changes to yellow when a limit is active
  5. Range – Current Pulley Selected

Spindle Warm Up

A spindle warm up cycle is important for all CNC machines, and especially important for machines that are not in a temperature controlled building.

  • The cycle lubricates spindle bearings.
  • It stabilizes spindle and machine temperature.
  • It reduces thermal expansion changes during startup.
  • It helps maintain machining accuracy.
  • It reduces premature bearing wear.

To configure a warm up cycle go to Configure ->Control->Settings tab.

  • Collapse all of the settings with the image.png button
  • Expand the Spindle section and scroll down to the Warm Up portion

Below are the default settings for the Spindle Warm Up.

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Parameter  Description
Spindle Warm Up Enabled Warm Up Cycle On or Off
Spindle Warm Up Inter-Lock with Cycle Start Yes or No
Spindle Warm UP Acknowledge Warm-Up Complete The operator will need to acknowledge that the warm up cycle completed
Spindle Warm Up MDI GCode Before Warm UP Provides an MDI field to enter GCode that will run before the Warm Up cycle begins
Spindle War Up Max RPM Max (finishing) speed for the warm up cycle. This should be the Max RPM of the spindle
Spindle Warm Up Min RPM Minimum (starting) speed for the warm up cycle (see note below). Set this to 1
Spindle Warm Up Steps How many steps will it take to get the spindle up to Warmed Up status - from Minimum to Maximum RPM
Spindle Warm Up Time Per Step How long it will stay in each Spindle Warm Up Step
Spindle Warm Up Off Time Trigger in minutes
 How long do want the spindle to be off before the spindle will need to run the Warm Up cycle
Spindle Warm Up Idle Speed Speed the spindle will idle at after the warm up is complete. Some spindles will not idle below 1500 RPM

Example:

  1. Locate the manufacturer's warm up instructions. If you do not have those instructions, then set 2 minutes at each step, 3 steps, ending 1 step below max spindle RPM.
  2. For the Spindle Warm Up Min RPM, enter 1. It will start at the correct RPM and run each step and time as you specified. 
  • High speed spindle example: max warm up RPM of 18000, 3 steps, 2 minutes at each step (18000/3 = 6000)
  • Standard Spindle example: Max warm up RPM of 2000, 3 steps, 2 minutes at each step (2000/3 = 667)
Setting High Speed Spindle Standard Spindle
Max RPM 18000 2000
Min RPM 1 1
Steps 3 3
Time per step
 2 2
system actions

2 min at 6000

2 min at 12000

2 min at 18000

run at the spindle warm-up idle speed

2 min at 667

2 min at 1333

2 min at 2000

run at the spindle warm-up idle speed

Constant Surface Speed

Constant surface speed is a spindle mode where the speed of the spindle changes based on the current X diameter position. The speed will increase as the X position goes to zero and the speed will decrease as the position moves away from centerline. This variation in speed will keep a constant amount of material moving under the tool tip. This mode produces superior finishes on the part.

Constant surface speed is turned on with G96. The current spindle speed will be interpreted as surface feet/minute while in G20 and surface meters/minute in G21. To leave constant surface speed mode, use G97 to return to RPM mode.

When using constant surface speed, it is important to have a G50 (spindle speed cap) defined. This prevents the spindle from overspeeding as the diameter goes to zero.

Machine Input / Output Control

For setting up machine specific IO, refer to the M31 Motion Control Setup Manual

Fixture Offsets

All G-Code files have their own coordinate system. In order to allow parts to be located on the table at any desired location, the part offset can be defined to adjust the actual location of the part on the table.

Part offsets can be defined and saved using G54-G59P120. The functionality is designed to allow different tooling setups to have predefined zero points to allow for streamlined setup.

You can view the fixture table and change the values directly by clicking the [Fixtures] tab. The values can also be set by using the MDI command to select the G-Code number for the fixture offsets to be stored in. Once the machine is at the desired zero position, zero Z by pressing the [Zero Z] button.

Turn Tip Types

The tip type (usually represented by a number) expresses the direction and useful paths of travel that a particular tool can cut. Most tips are "pointed" in a particular direction and have a limited angle at which they can cut. (There are no practical omnidirectional cutting tools on a lathe.) The tool tip type indicates which axis/axes you can cut along. The tip type also determines how tool nose compensation is applied. (See Lathe Tool Nose Radius Compensation for more details about compensation.)

In the following diagram, each tool type is shown, with the direction of X and Z where the tool is "pointing" and the cutting direction(s) indicated by the dotted lines.

   i.      Tool Tip Type defines the orientation in which a tool was zeroed, as if you were looking down onto the top face of the probe.

                                                ii.      Turning and Facing Tool: Tip Type 3

                                              iii.      Drills: Tip Type 7

                                               iv.      Part Off Tool (Zero on TSS): Tip Type 4

                                                 v.      Part Off Tool (Zero on HSS): Tip Type 3

                                               vi.      Boring Bar: Tip Type 2

In this diagram, +Z is to the right, and +X is up (the same as in the previous diagram).
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(Image Source: CNC Programming Handbook, 3rd Ed.; Peter Smid; p276)

These diagrams are for a rear-turret lathe. Some diagrams you may find will look (vertically) reversed because they are describing orientations for a front-turret lathe.

Lathe Tool Nose Radius Compensation

Turn Operations and Tip Types

Machinists will frequently associate tip types with types of turning.

  • Turning
    • cutting surface is in the -X direction
    • tip types: 2, 6, 1
  • Boring
    • cutting surface is in the +X direction (i.e. hollowing out the inside of something)
    • tip types: 3, 8, 4
  • Facing
    • cutting surface is in the -Z direction (i.e. removing material from the end, or "face," of the work piece)
    • tip types: 2, 7, 3
  • Back Facing
    • cutting surface is in the +Z direction (i.e. removing material from an "inside face" of a part)
    • tip types: 1, 5, 4

External Resources

http://www.mach-labs.com MachLabs Documentation support@machsupport.com

MachLabs Terms and Conditions

The MachLabs Team
14518 County Road 7240, Newburg, MO 65550
support@machsupport.com 

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