• The following videos give a much better explanation than this author can
• Where Mach3 is mentioned, we use bCNC

• A modified ICP 4030 CNC mill
• A computer-controlled, spinning cutter
• It can move in three directions:
  • Linearly in X, Y, Z
  • A fourth, rotary dimension (A) is planned
• It can cut many things:
  • Tested:
    • Aluminium
      • lubrication is critical
    • Titanium
      • the hackspace logo on the door was machined from titanium
      • lubrication is critical
      • slow cuts can cause work hardening
    • Steel - a small experiment has been carried out, more attempts needed
    • Wood, quite easily
  • Not tested, yet:
    • Plastics
    • Carbon composites
    • Human Fingers

• Power buttons
  • Box on the side of the machine
  • Controls power to the entire machine - including the computer
  • Hit the off button if a catastrophe is happening
• Cover
  • Hold the button to unlock the door
  • This only works when the machine has power
  • The spindle motor is interlocked to the cover - it will not turn when the cover is open. The cover
• Other buttons
  • They do nothing
  • Ideally, they will do something one day, but this is a low priority, so may not happen

Other computer aided manufacturing packages are available, but fusion 360 is a nice balance of useability vs. capability (and free for personal use)

• Don't cut your finger off
  • Don't touch the spinny bit
  • Don't open the cover when it is spinning
  • The spindle power is interlocked to the door. However, interlocks can fail!
• The mist cooler creates an oily fog
  • Don't breath this in
  • The portable dust extractor can plug in to the horrible jagged hole in the top of the enclosure. This seems to do a good job of filtering the oily mist
  • Did I mention that the hole is jagged and horrible?
• Dust clouds can be flammable
  • Especially true if cutting wood
  • The portable dust extractor can remove the dust cloud from the top of the machine
• Metal chips can scratch your eyes
  • They will likely get stuck to the door and then fall on you when you open it. Watch out for this!
• If you tell the machine to move, it will move, regardless of whether your fingers are in the way
• The compressor is extremely loud, and will probably start as soon as you power the machine on
  • warn others in the room, so they can use hearing protection

• Have you watched the videos linked further up the page?
  • watch them
• design your part in Fusion 360 - or CAD software of your choice
• use CAM (computer-aided manufacture) software to create the g code (.nc file) - ideally use Fusion 360 for this as well
• transfer this to the CNC mill computer
• on the desktop, press “run bCNC”
  • Wiki page for bCNC
  • this is the control software
• Connect to the machine through COM 4 (probably)
• press home
• zero each axis on the workpiece
  • you did set the origin to a sensible point didn't you?
• press play
• you will have made a mistake in your setup, accept this
  • PLACE YOUR HAND ON THE KILL SWITCH, READY TO PREVENT THE INEVITABLE CRASH!!!
  • grumble to yourself and others
  • try again

The result of poor Feed/Speed selection!

• Feerate: How fast the spindle is moved accross the workpiece (mm/min)
• Speed: How fast the spindle turns (RPM)
• The combination of these factors, along with the cut depth determines the forces on the tool
• The free mobile app FSWizard is very useful for selecting the right speed/feeds in an intuitive manner. https://app.fswizard.com/
• Because of the cheap spindle motor driver, the mill has very low power below 10'000 RPM. Therefore, it is better to use smaller tools, which use higher spindle speeds.
• Maximum spindle speed: 24'000 RPM

• A collet holds the tool nicely in the spindle
• Select the correct one for the diameter of the tool shaft
• Ensure it clicks fully into the holder on the spindle
• Insert the tool
• Tighten the holder onto the spindle using the big spanners

• Compressed air is used to spray a fine mist of cutting oil on to the material to be cut.
  • This is known as Mist coolant
  • For some reason, the control board thinks it is controlling a flood coolant system (where lots of liquid is dumped onto the part, like on our lathe)
  • Therefore, we must go along with this fiction, by telling Fusion 360/bCNC to turn on/off flood coolant, when we need the mist to operate
• Some materials (Aluminium, Titanium) absolutely require lubrication, as they try to stick to the cutting tool
• Other materials, e.g. wood, do not require it. However, the air blast will help to avoid chip recutting

• These two screws control Air and Oil flow
• If lubrication is required, it is desirable to use as little as possible
  • Using more than necessary probably won't improve the cut, but it will make a mess, and increase the risk of inhalation
• There is also an adjustment knob on the air compressor
  • LEAVE THIS AT OR BELOW 1
  • Experiments showed that turning this any higher resulted in the compressor overheating and seizing

Interesting and nerdy article on coolant strategies https://www.cnccookbook.com/cnc-coolant-system-mist-high-pressure-through-spindle/

• 400x300x140mm (XYZ)
• The table is larger: 600x375mm

• Yes, probably, or possibly no
• the machine is extremely versatile, so all eventualities can't be covered on a Wiki page
• don't be afraid to experiment, but be sensible when you do
• someone on youTube has probably done it. take a look

• This may happen at some point
• Clearly, you're smart enough to make the machine move. Therefore, attempt to repair it.
• Put a post on the google group
• Put a label on the machine

• Design the thing that you want to mill
  • Use Fusion 360 as it is easy to transfer designs from this into machine code
• Ask for an induction on the google group
  • The induction will be tailored around the part you are creating

• Alex R
• Felix H
• Mark P

Spindle / Spindle Mount / Inverter / Cooling Pump:

https://www.aliexpress.com/store/product/2-2kw-Water-Cooled-Spindle-CNC-wood-Router-2-2kw-220v-110v-VFD-80mm-Clamp-Water/214974_32965019931.html

https://zhonghuajiang.aliexpress.com/store/214974

Manufacturers Website

ICP 4030 CNC Manual

We appear to have these Stepper Drivers:

DM556T Stepper Driver Manual

This is the operating manual: ICP4030 Operating Manual

And this 5 Axis breakout Board:

5 Axis Breakout Board

Supporting Files

There is also an Arduino Nano controller with GRBL firmware in the cabinet:

Stepper motor information:

• Holding torque: 1.13nm
• Voltage per phase: 4.2a
• Step angle: 1.8° (200 steps per revolution)
• Angle error: ± 5
• Connection lines: 8

steps_per_mm = (steps_per_revolution*microsteps)/mm_per_rev