====== CNC Metal Mill (Tormach) Clearance ======

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====== Tool Specific Instruction ======

===== Point out the following tool features =====

  * Maintenance Tag
  * E-Stop
  * Main Power Switch
  * Motor Power Switch
  * Spindle Lockout Switch
  * Spindle and Coolant On/Off Switches
  * Spindle speed and direction control
  * Spindle cabinet, spindle lock, draw bolt
  * Control computer cabinet
  * Bed
  * End stops
  * Manual Oil Pump
  * Bed motion when moving in +X direction
  * Bed motion when moving in +Y direction
  * Motion when moving in +Z direction
  * Ways
  
===== Describe basic principles =====

  * Climb vs conventional milling.
  * Work vs work-holding
  * Spindle RPM vs Feed SFM
  * Relative cutting rate of steel (slow) vs aluminum (fast).
  * Tram
  * Measuring Equipment (calipers, micrometers, scales or rulers, dial indicators, edge finder. 
  * Types of machine code (GCODE), what a postprocessor is, and how to generate GCODE suitable for the Tormach.
  
===== Identify & mitigate common hazards =====

  * Metalworking when done properly is much quieter than woodworking.
  * Knows the common causes of noise and which hazards they indicate (vibration, deflection, dull tooling).
  * Heavy things – tooling, work holding equipment & workpieces.
  * Sharp things - cutting tools, chips, burrs on work piece.
  * Spinning things – spindle, axis wheels.
  * Identify 3 pinch points on the machine; recognize that the machine may move without warning unless locked out.
  * Hot things - chips, work piece, tools.
  * Toxic Fumes - avoid prohibited metals.
  * Hot flying debris - use appropriate tools, work holding, coolant, and clear work area.

===== Allowable Materials =====

  * Name 4 common materials allowed on the CNC
  * Name 1 material that is not allowed on the CNC router

===== Safe Setup / Operation / Cleanup =====

The section below may be cleared with no stock material present, but with a tool in the spindle. Demonstrate:

  * manual on/off of spindle and coolant flow
  * using the MDI and a GCODE command to move the spindle to a specific position in XYZ.
  * setting one axis to a specific value (e.g. set X to 0.5")
  * slow and fast jogging in X, Y, and Z
  * identifying, then changing the spindle belt configuration (low->high speed or vise versa)

The section below may be cleared using the "first part" file located on the machine control interface (C:\PCNC3\GCode\FirstPart.nc). Demonstrate:

  * proper work-holding.
  * proper feed and speed selection.
  * proper cutting tool selection.
  * proper cutting tool installation.
  * proper zeroing of cutting tool
  * loading GCODE into the machine control interface
  * proper zeroing (and ref-ing) of the machine
  * proper feeds and speeds selection.
  * proper mounting of workpiece
  * running a GCODE job
  * cleaning the CNC and returning the bed to its original state 
  * removing all fixtures, cutting bits, and the collet after use and returning them to storage.

Additionally, the following rules apply during operation:

  * Only run GCODE files off the control computer directly and never via USB flash drive or SD card.
  * **Regularly oil the machine (every 4hrs of operation or 48hrs left idle)**

===== Knowledge and Technique =====

Demonstrate:
 
  * proper PPE.
  * how to properly use the motion pendant for fine adjustment.
  * proper protocol in the event that the machine breaks.
  * proper cleanup.
  * what to check on if the Mill is making a lot of noise.
  * knowledge of when and how to use the coolant system.