Desktop Mill Projects

Name on Mill Project

Today, I worked on the desktop mill to create a custom design of my name. Starting with a sketch grid, I programmed the machine using X, Y, and Z coordinates to guide its movements. Throughout the process, I encountered several challenges, including incorrect values and programming errors, but each mistake taught me something new about the operation of the mill. This write-up outlines my step-by-step experience, the adjustments I made, and the lessons I learned along the way.

I began by writing my name on a sketch grid and creating a design based on my name. I then used X, Y, and Z coordinates to program the desktop mill.

Through trial and error, I refined my process and gained a better understanding of programming and operating the desktop mill.

How i wrote my G-Code

I wrote my name on a free sketch grid website in a 5x5 box. making sure i scale down the little boxes inside to make sure my measurements are accurate. There were 4 mini boxes in a single box, so i found that each little box is .25. I then plotted the critical points in my drawing and used my finger to trace and act like the pen to help me visualize the pathway of the tool instead of just looking at numbers.

I will provide my G code at the very bottom of the page.

Process of loading G-code into Desktop Mill

The process of loading my G-Code everytime i updated it was the following:

Download G-Code onto USB drive
Click select programs on pendant
Go to USB tab and click on my .txt file
Click F2 to transfer it to memory
Then all there is left is to click cycle start

First attempt

First Attempt: The right side of the “A” in my design moved in the opposite direction. After reviewing my code, I noticed that I had used an incorrect coordinate. I changed the X2 value to X1.9, not realizing the issue was due to the lack of a decimal point after the number. The machine misinterpreted the value as a whole number.

Attempt #2

I fixed the X2 issue and reloaded the program. However, this time, the Z-axis failed to lift the pen when needed. Again, I had forgotten to add a decimal point to the Z value.

Attempt #3

I corrected the decimal issue but accidentally set the Z value to 3. When I ran the program, the machine stopped and displayed an error message indicating the Z value exceeded the maximum range (2.22). It was slowly but surely coming together

Attempt #4

I realized the importance of adding decimal points to all values. I changed the Z value to 1.0 and corrected all missing decimals in my border lines.

Finished Product!

After addressing all the issues, I finally got the program and the writing exactly how I wanted it. After alot of trial and error, i got the finished product!

Lessons Learned

Always Use Decimal Points: I learned the critical importance of including decimal points in my XYZ values to ensure the machine interprets them correctly. This small detail caused several issues until I understood its significance.
1. Navigating the Pendant and Setting Offsets: I practiced using the pendant to set offsets with G-code by positioning the pen where I wanted it and inputting the coordinates to set the work offset to G55.
2. Using Tool Offset Feature: I learned to adjust the tool offset measure before each run. As paper was removed with each attempt, the ink became faded. By handle jogging the pen until it firmly touched the paper and pressing the tool offset measure button, I ensured consistent ink opacity.

Finished, hand written G-Code

O1111

(Layth Al Hamadani)

(Tool list)

(T01-Pen)

G00 G90 G55 X0 Y0

G43 H01 Z.1

X0.25 Y-0.25

Z0.

Y-4.75

X1.25

X1.5 Y-0.25

X1.90 Y-4.75

X2.75 Y-0.25

X3.75

Y-4.75

Z3.

X4.75 Y-0.25

Z0.

Y-4.75

Z3.

X3.25 Y-0.25

Z0.

X3.25 Y-4.75

Z3.

X5. Y-2.5

Z0.

X0. Y-2.5

Z3.

X1.75 Y-0.25

Z0.

X2.5 Y-1.75

Z3.

X0 Y0

Z0.

X5. Y0.

X5. Y-5.

X0. Y-5.

X0. Y0.

Z3.

Project #2: Letter with Radii

For this project, I decided to take on the challenge of adding radiuses to my designs. I started by working with letters on the Sketch Grid website, creating two designs. Unfortunately, both attempts failed because I miscalculated the radiuses and the distances needed to plot my points accurately. This made the process frustrating and difficult to manage.

Switching to Fusion 360

After struggling with Sketch Grid, I decided to try Fusion 360—and it turned out to be a game-changer. The software was much more intuitive and had features that made the process simpler. I designed my final letter, “F,” using Fusion 360 and relied on its Inspect tool to calculate precise measurements for my design. This feature, which Sketch Grid lacked, saved me a lot of time and effort. Armed with accurate measurements using the inspect tool, I successfully plotted my points and coded them for the machining process.

Testing on the Desktop Mill

I ran my design on the desktop mill for the first time, but I encountered an issue: a miscalculated Y value caused one of the lines to go down instead of up. Although it was frustrating to see an error in my work, I was able to quickly identify and fix the problem in the code. Once I corrected the error, I ran the mill again, and this time, I achieved the final design I envisioned.

Lessons Learned

This taught me how to incorporate and manually write G-Code using radii. This project also taught me a valuable lesson: patience and a clear mind are essential for overcoming challenges. My frustration during the initial stages made it harder to think clearly, but switching to a better tool like Fusion 360 simplified the process and helped me regain focus. By persevering and adapting, I was able to overcome the difficulties and complete the project successfully.

G-Code

O11111

(Layth Al Hamadani)

(Letter Outline)

G00 G17 G20 G58 X0 Y0

G43 H1 Z1

X.25 Y-.50

X.50 Y-.75

Z0.

G2 F50. R1.75 X4. Y-0.75

G2 F50. R0.125 X3.75 Y-1.

Z1.

X4. Y1.

Z0.

G3 F50. R4. X2. Y-1.

G2 F50. R3. X0.50 Y-1.

G1 X0.50 Y-0.75

Z1.

X3. Y-0.75

Z0.

G3 F50. R4.75 X3.25 Y-3.125

Z1.

X3.25 Y-0.75

Z0.

G3 F50. R4.5 X3.25 Y-3.

Z1.

X2. Y-1.75

Z0.

G3 F50. R0.5 X2. Y-2.

G3 F50. R4.125 X4.125 Y-2.

G3 F50. R0.5 X3.75 Y-1.75

G2 F50. R3.5 X2. Y-1.75

M30

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