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This document describes the setup of the machine, some of its dimensional limits, use of the Roland SRP Player software (for generating toolpaths from STL files), and some aspects of the process whereby an .RML NC file from MasterCAM is used. (It could use some significant improvements.Harvard GSD )

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nameGuide to Roland MDX-40-A_2022.pdf
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Template Files

Below is an empty MasterCAM template files with a number of supported toolpaths included. The settings assume that 2" foam material is being used, so changes would be necessary for other material characteristics. Only one tool is Four tools are defined, so if using a different tool other than one included, a new tool will have to be defined. It is necessary that toolpaths using different tools be posted separately so that each tool can have a new Z calibrated on the machine between toolpaths.

 

 

Warning
iconfalse
titleNot Recommended: Fanuc Machine Definition and Post Processor

 

 

Info
iconfalse
titleRecommended: Template File for Fanuc Machine Definition and Post Processor

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nameROLAND_TEMPLATE.emcx-9
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Template Files on Sharepoint: Foam_Small_Roland_Mill

This template file includes a Drill operation and is intended to be used with the Fanuc Machine Definition, Control, and Post Process (see below).

Review the NC File

There are two post-processors that you can select in MasterCAM to output an NC file for the Roland Mill, depending on which you choose, there are different steps involvedwe recommend using the "Fanuc 3X Mill" machine definition as there are problems and limitations related to the Roland machine definition and post.

Info
iconfalse
titleRecommended: Fanuc Machine Definition and Post Processor

The files that are most up-to-date can be found on Goliath:\Software\Mastercam\Folder_Migrate_MCX_X9\* and are also saved on the computer connected to the Roland Mill.

The Fanuc 3 Axis Mill Machine Definition, Control, and Post Processor will output an .NC file. This .NC file should be reviewed for errors and needed corrections before it is run on the Roland Mill. Do this within MasterCAM's code editor.

  • Check for the correct Spindle Speed and Feedrate for the tool.  This can be done by searching for M3 (spindle ON) and G1 (move with feedrate).

The speed is indicated by the Sxxxxx setting near the M3 (spindle ON/CW) command at the beginning of the program.   The speed is given in RPM and the range is 4500-15000, for most tools and materials we will run near the top of the range.  An example can be found on line number N130 with a G0, G90, G54 and then Z1.5 followed by the speed and spindle ON: N130G0G90G54Z1.5S15000M3

The feedrate for the Roland will vary from 30 IPM (inches per minute) to 120 IPM max.  For low density foam, we can take light cuts at 70-90 IPM and G0 rapid/retract rates will be at the max of 120 IPM.  The standard chipload charts are a reasonable place to start, but may have to be adjusted downward to meet the limitations of the machine.  Look for the G1 commands and they will contain an F (feedrate) setting.  An example here can be found at line number N160, with a G1 to Z.75 followed by a feedrate of 90 IPM:  N160G1Z.75F90.

  • Check for Z0 and Z-, to prevent cutting into the machine table, this can be done by searching.
  • Check for X- and Y-.  This does not cause damage, but if G54 is set to the physical 0,0 (bottom left) then the machine will not move into negative territory.  You can shift your model slightly and adjust stock on the table to compensate.
  • Return to MasterCAM and make corrections there, if either of the above conditions need to be corrected.

Things to note:

  • In the VPanel, users must set the 0,0,0 of the "G54" coordinate system before cutting the RML file.

  • The NC file does contain the spindle speed as defined in MasterCAM for the tool/toolpath.
  • Coordinates are displayed in inches.
  • Drilling operations are supported.
  • Toolchanges are not supported by the Roland MDX-40A. MCX files that use multiple tools must output the toolpaths for different tools separately and re-calibrate a new Z for each toolchange.
Warning
iconfalse
titleNot Recommended: Roland Machine Definition and Post Processor

The files that are most up-to-date can be found on Goliath:\Software\Mastercam\Folder_Migrate_MCX_X9\* and are also saved on the computer connected to the Roland Mill.

The Roland Machine Definition and Post Processor will output an .RML file. Although not as easy to "read" as other types of NC files, the .RML file should be reviewed for needed corrections before it is run on the Roland Mill. Do this within MasterCAM's code editor or a text editor of your choosing.

  • Ensure that the first line of the file reads "!MC 1" and not "!1", otherwise the spindle will not start.
  • Ensure that the the last line of the file reads "!MC 0", rather than "!0" in order to stop the spindle 
  • (There may be a line at the start and end of the file that read "H", this is OK, as it tells the machine to rapid to its home position.
  • Ensure that any edited file is saved with an extension of .RML (some text editors will save it with a .NC or a .TXT, which might have to be removed)

Things to note:

  • In the VPanel, users must set the 0,0,0 of the "User Coordinate System" before cutting the RML file.
  • The RML does NOT contain spindle speeds, so this must be controlled by setting it in the VPanel interface.
  • Coordinates are displayed in 1/100 mm regardless of MCX file unitsWhen aborting a job the machine will NOT automatically retract to a safe location: make sure you manually lift the tool up above the stock before resuming or starting a new job, etc.
  • Toolchanges are not supported by the Roland MDX-40A. MCX files that use multiple tools must output the toolpaths for different tools separately and re-calibrate a new Z for each toolchange.Drilling Operations are NOT supported by the Roland Machine Definition and Post Processor. Units for these toolpath types are output as inches, rather than 1/100 mm, so do not cut correctly.