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Haas Automation is the largest producer of consumer CNC machines in the world, as such they have a library of training modules to accompany their products.
The following is an overview of the Haas Automation basic Mill operator course.
Types and History
As with the saw operator the mill operator has gone through significant iteration changes through its history, with changes in technology being implemented in each new version.
In the first module of the Haas training program reviews the history of the mill is reviewed.
The Hand drill
With a history spanning over 35,000 years, the Drill is a tool that has helped man shape objects with a high level of time input and low level of precision.
Drill press/Electric drill
Moving into the Industrial Age the Drill-press and powered Drill made their debut. These drills helped man shape objects with moderate precision and a moderate level of time investment.
Manual Mill
Shortly after the drill press the Manual mill appeared. This machine is capable of High precision and a low to moderate time investment.
The CNC Mill
In the 1960s aerospace industry moved toward a numerically controlled mill system with very basic mechanical data inputs through punch cards. This later graduated to a computer controlled system and the Computer Numeric Control (CNC) machine was born!
In 1983 Gene Haas founded Haas Automation and brought the first real consumer available CNC Machines to market.
Basic safety
As also covered in on the previous page; in the second module basic safety and best practices are covered.
Personal Protective Equipment and safe operation practices are introduced.
The default for troubleshooting issues of "checking with your supervisor "is also established.
Start-up and Warm-up
In the third module the basic start and warm-up procedures are reviewed, followed by instruction on what to do if you need to stop the machine.
The first portion covers a warm-up program and the common checks to be familiar with at the beginning of the day.
There are three methods of stopping a working machine all located on the control panel:
Feed Hold button
Reset button
Emergency stop button (E-Stop)
Shut-down procedures
Shut down procedures as well as best practices for machine health are discussed next.
The importance of keeping the machine's different components clean and the effects that can occur if they are not well taken care of are discussed.
Functions and Basic Operation
In this Module basics of the operation are covered. From loading and unloading, simple programs and different tools and their application.
Loading and unloading parts
In this section the different types of vices are discussed and the importance of loading them properly. Properly loading a part into a includes: making sure the vice is properly installed and tightened to the X/Y access table, making sure the vice is clear of chips and debris, making sure that the part seats in a repeatable way on the vice.
Starting procedure for work on a device and the importance of being ready to stop the machine in-case of an error are also discussed
Simple programs
In this section the programming language used by the machines is introduced.
Programs, before they are uploaded, are assigned a numeric code beginning with the letter "O" followed by five numbers.
G-code is introduced as the main language of communicating instruction to the machine
M-codes are a commands directed to the machine to do things like change a tool
T-codes are used to identify specific tools
Control functions
In this section we go further into the different controls on the control panel and how to use them when operating the machine.
Alpha keys, allow the operator to input text when required.
Numeric keys, allow the operator to input numerical entries
Cursor keys, allow for navigation through the program
Function keys, these keys include the 'Reset' button, 'Power up/Restart' button and 'Recover' buttons. there are also four F# function keys that will be assigned various functions based off of the screen you are in.
Tool offset and tool change buttons are also in this section.
Display keys, will allow for the quick navigation through different screens
Mode keys, are further divided in to six sections that allow for editing, memory recounting, control of the machine through a more manual control with the use of the 'hand jog', Program avigation buttons, as well as 'zeroing' the machine to home.
Jog keys, these keys are used for moving the cutting table about the machine in a manual fashion
Override keys, these keys allow the operator to "override" the machines program when it come to speed and feed rate.
Tools used and their application
In this section the different tools are covered as well as their functions and applications.
Twist Drills and Insert Drills; these are used for cutting holes
End Mills are used to cut material along the rotating axis with a rounded end, various chamfer degrees, or 90 degree edge, and Face Mills that are used to cut faces perpendicular to the rotating axis
Slot-mills are used as the name suggests to cut lots perpendicular to the rotating axis.
Milling cutters can be made in all kinds of shapes and sizes with the arrangement of replaceable cutting edges.
Taps for creating threaded holes are discussed. These tools require that a set rate of feed is applied when threading a hole.
Finally we talked about the importance of choosing the correct cutters for in cut certain materials, in particular the correct cutters when cutting Aluminum and harder steels.
Basic machinist measuring and procedural work
In the next three modules measuring terminology, basic math involved in machine processes, as well as the appropriate measuring tools to use and how to use them is discussed.
Math
For the basic math portion the different measures of an inch are discussed. Inches are not expressed fractionally but instead are decimally expressed. The common denomination for the inch is the thousandth referred to as "Thou".
Blue-Print and drawings reading are also covered.
This is important as the part produced needs to match the Drawing which also needs to match the program file.
Also understanding how to read a drawing is very important when it comes to inspecting a part to see if the job was done correctly and within tolerance.
Good house keeping
Mill Maintenance and best practices.
In the final section of the training course Mill maintenance is discussed. This section includes: spindle condition and when a spindle should not be used, health of the of the coolant, proper procedures for cleaning the chips from the machine, proper care and attention to the condition of the tool studs, as well as the air supply condition.
It is important that the air supplied to the machine is free of water and contaminates as well as stays within the correct air pressures.
After completing the Haas training there is an option to schedule an in-person certifying Test to show you are a capable operator of a Haas machine.
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