Coolant
Cutter type, material and diameter
Cutting Depth
As a general rule:
Lower spindle speeds are used to machine hard or tough material or where heavy cuts are
taken.
Higher spindle speeds are used to machine softer materials in order to achieve better surface
finishes. Higher speeds also apply when using small diameter cutters for light cuts on frail
work pieces and delicate setups.
Note: Cutter diameter greatly affects spindle speeds. The larger the diameter, the lower the spindle
speed.
4.1.4.2
Feedrates
Factors that affect feedrates:
Depth and width of cut
Design or type of cutter
Sharpness of the cutter
Workpiece material
Type of finish or accuracy required
Climb or conventional milling
If a fine finish is required, reduce the feed rather than increase the spindle speed. Cutters are dulled
by high spindle speeds rather than high feedrates.
4.2 The Mechanical Drive Train (X, Y)
Indications:
Troubleshooting instructions indicate that the drive train is potentially the problem and other
(more easily checked variables) have been exhausted.
Roughness, looseness, tightness or jamming movement in the table or saddle.
Actions:
1. Check for machine considerations, especially gib adjustments. See Gib Adjustments section
2. Check the torque of the axis in three places (both ends and centre of ball screw) along the length
of the ball screw. The torque should be the same within 2 or 3 in-lbs across the length of the ball
screw. If it is not, chances are the ball screw is misaligned. A misaligned ball screw can lead to
parts being out of round and servo problems at low feedrates. A bad ball screw can also cause
high torque, although this is highly unlikely. See Sections 4.2.1 and 4.2.2 for more information.
The following steps take you in logical sequence through the machine assemblies. For drawings of these
assemblies see Section 5. These instructions break the machine down from fully assembled and point out
the areas to look at specifically:
1. Check that the belt is properly tightened. A loose belt can lead to excessive backlash
compensation values on motor encoder only machines. To adjust belt tension, loosen the (4)
screws that secure the motor to the bracket. Adjust motor for proper belt tension as necessary.
See the drawings for illustrations.
2. Check that the nut that tightens up against the ball screw pulley is tight. If this is loose the pulley
may not run true on the ball screw.
3. 2500 & 3500 X-axis only - Check that the tapered sleeve that seats the pulley has not clamped to
the ball screw prematurely. It should be seated firmly against the pulley. Tightening the nut may
not have ensured this. Also make sure the pulley is keyed to the ball screw.
4. 2500 & 3500 X-axis & Y-axis bearing housings - Ensure that the bearing housing is clamped in
place by the bracket. This design uses the bracket to secure the bearing housing in place. It
should not allow the bearing housing to float between the bracket and machine. For the 4000 &
5000, verify the bearing housing cover is properly fastened.
5. 2500 & 3500 X-axis & y-axis - Ensure that the Clamp Nut is secured. The following applies to the
clamp nut:
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