SOP for the Mekanika Pro Education Pack CNC milling machine

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1. Purpose

To ensure safe and efficient operation of the Mekanika Pro CNC milling machine within educational or public spaces, preventing accidents and ensuring high-quality results.

2. Scope

Applies to all operators, supervisors, and maintenance personnel responsible for using or servicing the CNC mill at premises of GHE, ETH Zurich.

3. Responsibilities

  • Operators: Follow all procedures and safety guidelines.
  • Supervisors: Ensure all staff are trained and SOPs are followed.
  • Maintenance: Carry out routine checks and preventive maintenance.

4. Required Equipment

  • Mekanika Pro CNC mill + PC & VFD spindle
  • Tooling: end mills, collets, wrenches
  • Spoilerboard, safety enclosure, dust shoe and dust collection system
  • PPE: safety glasses, hearing protection, dust mask
  • Clamping/tools for workpiece
  • Measurement instruments: calipers, gauges
  • Appropriate lubricants/coolants if needed

5. Safety Precautions

  • Always wear appropriate PPE: safety glasses, gloves, and hearing protection.
  • Ensure the safety enclosure is fully closed before starting any operation. The enclosure doors are interlocked to trigger an emergency stop if opened.
  • Never bypass safety interlocks.
  • Check that emergency stops and all controls are working before use.
  • Keep the area clean, dry, and well-lit.
  • Only trained personnel are permitted to operate the CNC mill.

6. Pre-Operation Procedure

  1. Inspect Machine:
    • Check for any visible damage, loose or missing parts.
    • Ensure the worktable and spoilerboard are clear of debris.
    • Confirm all guards/enclosures are in place and secure.
  2. Prepare Tooling:
    • Select appropriate end mill and collet size.
    • Inspect the tool for wear or damage.
    • Install end mill into spindle using both provided wrenches.
  3. Prepare Workpiece:
    • Attach securely to the spoilerboard/worktable using appropriate clamps. Double-check tightness.
  4. Set Up Dust Collection:
    • Attach dust shoe and connect the dust extraction system.
    • Ensure vacuum is functional before starting spindle.
  5. Power Up:
    • Turn on the CNC machine and control PC. Confirm all system lights/status indicators are normal.

7. Operation

  1. Load/Check Program:
    • Load G-Code file via touchscreen, USB, or network connection.
    • Double-check that the program matches the intended job (material, tool diameter, etc.).
  2. Pre-Run Checks:
    • Use ‘dry run’ (without spindle engaged or at reduced speed) to verify there are no collisions in the toolpath.
    • Visually confirm the machine moves as expected.
  3. Start Job:
    • Ensure all operators/observers are clear.
    • Start dust collection system.
    • Start spindle and machining program via control interface.
    • Monitor operation; remain alert for unusual noises, vibrations, or errors.

8. Emergency Procedures

  • Use the EMERGENCY STOP button or open the enclosure door to stop the machine immediately if a hazard arises.
  • Report any incident to the supervisor and do not resume operation until the cause is identified and fixed.

9. Post-Operation

  1. Job Completion:
    • Wait for all movement to stop, then remove finished part.
    • Inspect both part and tooling for issues.
  2. Clean-Up:
    • Use vacuum to clear debris from machine and work area.
    • Remove and store tools, collets, and clamps properly.
  3. Shutdown:
    • Turn off spindle, dust collector, and CNC system.
    • Power down the control PC.
    • Ensure enclosure is closed and workspace is tidy and safe.

10. Maintenance

  • Perform regular checks on spindle, tool holders, and safety features.
  • Inspect dust filters and empty collection bins as required.
  • Log maintenance in provided records or checklists.