Skills
skills/robdtaylor/personal-ai-infrastructure/cncsetup

cncsetup

SKILL.md

CNCSetup - MNMUK Setup Sheet Generator

Purpose: Standardized setup documentation to reduce setup time, prevent errors, and capture tribal knowledge.

When to Activate

  • "Create a setup sheet for [part/job]"
  • "Setup for [machine name]"
  • "New job setup on the NLX2500"
  • "Tooling list for [operation]"
  • "Document the setup for [part number]"

Setup Sheet Templates by Machine Type

DMG MORI 5-AXIS MILLS (NMV3000, DMU50, NHX500)

# SETUP SHEET - 5-AXIS MILLING

## Job Information
| Field | Value |
|-------|-------|
| Part Number | |
| Part Name | |
| Customer | |
| Operation | |
| Machine | [ ] NMV3000  [ ] DMU50  [ ] NHX500 |
| Program Number | |
| Setup By | |
| Date | |

## Workholding
| Item | Details |
|------|---------|
| Fixture ID | |
| Fixture Location | |
| Clamping Method | |
| Clamping Torque | Nm |
| Pallet Number | |
| Datum/WCS | G54 / G55 / Other: |

## Work Offset Setup
| Axis | Value | Method |
|------|-------|--------|
| X | | Probe / Edge finder / Indicator |
| Y | | Probe / Edge finder / Indicator |
| Z | | Probe / Tool setter |
| A | | |
| B/C | | |

## Tool List
| T# | Description | Diameter | Length | Offset | Notes |
|----|-------------|----------|--------|--------|-------|
| T1 | | | | H1 D1 | |
| T2 | | | | H2 D2 | |
| T3 | | | | H3 D3 | |
| T4 | | | | H4 D4 | |
| T5 | | | | H5 D5 | |

## CELOS Settings
| Parameter | Value |
|-----------|-------|
| Spindle Warm-up | [ ] Required  [ ] Not Required |
| Coolant Type | [ ] Flood  [ ] Through-spindle  [ ] Mist |
| Coolant Pressure | bar |
| Chip Conveyor | [ ] On  [ ] Off |

## Critical Dimensions (First-Off Check)
| Feature | Nominal | Tolerance | Actual | OK |
|---------|---------|-----------|--------|-----|
| | | ± | | [ ] |
| | | ± | | [ ] |
| | | ± | | [ ] |

## Safety & Notes
- [ ] Guards in place
- [ ] Correct PPE worn
- [ ] Program proven at reduced feed

### Special Instructions:


### Known Issues / Tips:

DMG MORI TURNING CENTRES (NLX2500, ALX2000)

# SETUP SHEET - CNC TURNING

## Job Information
| Field | Value |
|-------|-------|
| Part Number | |
| Part Name | |
| Customer | |
| Operation | OP10 / OP20 / Complete |
| Machine | [ ] NLX2500 Twin  [ ] NLX2500 Single  [ ] ALX2000 |
| Program Number | |
| Setup By | |
| Date | |

## Material & Stock
| Item | Details |
|------|---------|
| Material | |
| Stock Type | [ ] Bar  [ ] Billet  [ ] Forging  [ ] Casting |
| Stock Size | Ø x L mm |
| Bar Feeder | [ ] Yes  [ ] No |
| Bar Stop Position | mm from chuck face |

## Workholding - Main Spindle
| Item | Details |
|------|---------|
| Chuck Type | [ ] 3-jaw  [ ] Collet  [ ] Special |
| Chuck ID/Size | |
| Jaw Type | [ ] Hard  [ ] Soft  [ ] Pie jaws |
| Jaw Bore | Ø mm |
| Grip Length | mm |
| Clamping Pressure | bar |

## Workholding - Sub Spindle (if applicable)
| Item | Details |
|------|---------|
| Chuck Type | [ ] 3-jaw  [ ] Collet |
| Jaw Type | [ ] Hard  [ ] Soft |
| Grip Length | mm |
| Part-off Position | mm |
| Transfer Method | |

## Work Offset Setup
| Offset | Value | Method |
|--------|-------|--------|
| Z (Face) | | Touch-off / Probe |
| X (Diameter) | | Test cut / Probe |

## Tool List - Turret
| T# | Station | Description | Insert | Orientation | Offset | Notes |
|----|---------|-------------|--------|-------------|--------|-------|
| T1 | | | | | | |
| T2 | | | | | | |
| T3 | | | | | | |
| T4 | | | | | | |

## Live Tooling (if applicable)
| T# | Station | Description | RPM | Notes |
|----|---------|-------------|-----|-------|
| | | | | |

## Cutting Parameters Reference
| Operation | Speed (m/min) | Feed (mm/rev) | DOC (mm) |
|-----------|---------------|---------------|----------|
| Rough OD | | | |
| Finish OD | | | |
| Rough ID | | | |
| Finish ID | | | |
| Thread | | | |
| Part-off | | | |

## Coolant Settings
| Parameter | Value |
|-----------|-------|
| Coolant Type | [ ] Flood  [ ] High-pressure |
| HP Coolant Pressure | bar |
| Chip Conveyor | [ ] On  Direction: |

## Critical Dimensions (First-Off)
| Feature | Nominal | Tolerance | Actual | OK |
|---------|---------|-----------|--------|-----|
| OD 1 | Ø | ± | | [ ] |
| OD 2 | Ø | ± | | [ ] |
| Length | | ± | | [ ] |
| Thread | | Class | | [ ] |

## Cycle Time
| Phase | Time |
|-------|------|
| Load | sec |
| Cut Cycle | sec |
| Unload | sec |
| **Total** | sec |

### Special Instructions:


### Known Issues / Tips:

HARDINGE TWIN SPINDLE TURNING

# SETUP SHEET - HARDINGE TURNING

## Job Information
| Field | Value |
|-------|-------|
| Part Number | |
| Part Name | |
| Operation | |
| Program Number | |
| Setup By | |
| Date | |

## Stock
| Item | Details |
|------|---------|
| Material | |
| Stock Size | Ø x L mm |
| Bar Feed | [ ] Yes  [ ] No |

## Workholding
| Spindle | Chuck | Collet/Jaw | Grip | Pressure |
|---------|-------|------------|------|----------|
| Main | | | mm | bar |
| Sub | | | mm | bar |

## Precision Notes (±0.003mm capability)
| Parameter | Setting |
|-----------|---------|
| Warm-up Cycle | [ ] Required - Run time: min |
| Temperature Stability | [ ] Verified |
| Probe Calibration | [ ] Verified |

## Tool List
| T# | Description | Insert | Offset | Notes |
|----|-------------|--------|--------|-------|
| | | | | |

## Critical Dimensions
| Feature | Nominal | Tol | Gage | Method |
|---------|---------|-----|------|--------|
| | | ±0.003 | | |

### Precision Tips:
- Allow 20-min spindle warm-up for best tolerance
- Verify coolant temperature stable
- Use in-process gauging for critical features

CITIZEN SWISS-TYPE (Sliding Head)

# SETUP SHEET - CITIZEN SWISS

## Job Information
| Field | Value |
|-------|-------|
| Part Number | |
| Part Name | |
| Machine | [ ] Citizen Laser Head  [ ] Citizen LFV |
| Program Number | |
| Setup By | |
| Date | |

## Material & Bar Stock
| Item | Details |
|------|---------|
| Material | |
| Bar Diameter | Ø mm (max Ø38.1mm) |
| Bar Length | mm |
| Bar Supplier/Heat | |

## Guide Bushing Setup
| Parameter | Value |
|-----------|-------|
| Guide Bushing Size | Ø mm |
| Bushing Type | [ ] Rotating  [ ] Fixed |
| Bushing Material | [ ] Carbide  [ ] Bronze |
| Z-axis Reference | mm |

## Main Spindle Collet
| Parameter | Value |
|-----------|-------|
| Collet Size | Ø mm |
| Clamping Pressure | bar |
| Stock Stick-out | mm |

## Sub Spindle Setup
| Parameter | Value |
|-----------|-------|
| Collet Size | Ø mm |
| Pickup Position | Z = mm |
| Grip Length | mm |

## Tool List - Gang Slide
| Position | Tool | Insert/Size | Offset | Notes |
|----------|------|-------------|--------|-------|
| | | | | |
| | | | | |
| | | | | |

## Tool List - Back Working
| Position | Tool | Insert/Size | Notes |
|----------|------|-------------|-------|
| | | | |
| | | | |

## LFV Settings (if LFV machine)
| Parameter | Value |
|-----------|-------|
| LFV Mode | [ ] On  [ ] Off |
| Oscillation Frequency | Hz |
| Amplitude | mm |
| Applied To | [ ] OD  [ ] ID  [ ] Drilling |

## Laser Head Settings (if Laser machine)
| Parameter | Value |
|-----------|-------|
| Laser Operation | [ ] Marking  [ ] Cutting  [ ] N/A |
| Power | W |
| Program | |

## Coolant
| Type | Setting |
|------|---------|
| Oil Type | |
| Pressure | bar |
| Mist | [ ] On  [ ] Off |

## Critical Dimensions (±0.003mm capability)
| Feature | Nominal | Tol | Method |
|---------|---------|-----|--------|
| | | ± | |
| | | ± | |

## Cycle Time Target
| | Time |
|--|------|
| Cycle | sec |
| Parts/Hour | |

### Swiss-Specific Tips:
- Verify guide bushing alignment before production
- Check oil level and filtration
- LFV excellent for 316SS and titanium chip breaking
- Monitor bar remnant length

MITSUBISHI EDM (Wire & Spark)

# SETUP SHEET - EDM

## Job Information
| Field | Value |
|-------|-------|
| Part Number | |
| Part Name | |
| Machine | [ ] Wire EDM  [ ] Spark EDM |
| Program Number | |
| Setup By | |
| Date | |

## Workpiece
| Item | Details |
|------|---------|
| Material | |
| Hardness | HRC |
| Dimensions | L x W x H mm |
| Weight | kg |

---

## WIRE EDM SETUP

### Wire Settings
| Parameter | Value |
|-----------|-------|
| Wire Type | [ ] Brass  [ ] Coated  [ ] Other: |
| Wire Diameter | mm |
| Wire Tension | g |
| Wire Speed | m/min |

### Workholding
| Item | Details |
|------|---------|
| Fixture Type | |
| Leveling | [ ] Verified |
| Start Hole | X: Y: (if applicable) |

### Cutting Parameters
| Pass | Power | On-Time | Off-Time | Wire Speed | Offset |
|------|-------|---------|----------|------------|--------|
| Rough | | μs | μs | m/min | mm |
| Semi | | μs | μs | m/min | mm |
| Finish | | μs | μs | m/min | mm |
| Skim | | μs | μs | m/min | mm |

### Flushing
| Parameter | Value |
|-----------|-------|
| Upper Nozzle | mm gap |
| Lower Nozzle | mm gap |
| Flushing Pressure | bar |
| Submerged | [ ] Yes  [ ] No |

---

## SPARK EDM (SINKER) SETUP

### Electrode
| Parameter | Value |
|-----------|-------|
| Electrode Material | [ ] Copper  [ ] Graphite |
| Electrode ID | |
| Undersize | mm |
| Polarity | [ ] +  [ ] - |

### Cutting Parameters
| Phase | Current | On-Time | Off-Time | Depth |
|-------|---------|---------|----------|-------|
| Rough | A | μs | μs | mm |
| Semi | A | μs | μs | mm |
| Finish | A | μs | μs | mm |

### Flushing
| Method | Setting |
|--------|---------|
| Type | [ ] Jet  [ ] Suction  [ ] Orbital |
| Pressure | bar |
| Retract Height | mm |
| Jump Frequency | |

---

## Dielectric
| Parameter | Value |
|-----------|-------|
| Type | |
| Level | [ ] Verified |
| Filter Status | [ ] OK |
| Conductivity | μS |

## Critical Dimensions (Wire: ±0.004mm, Spark: ±0.050mm)
| Feature | Nominal | Tol | Actual | OK |
|---------|---------|-----|--------|-----|
| | | ± | | [ ] |

### EDM Tips:
- Wire: Check wire path and guides before start
- Spark: Verify electrode alignment with workpiece
- Monitor dielectric condition
- Log electrode wear for repeat jobs

HAAS FAST RESPONSE CELL (Mini Mill & Tool Room Lathe)

# SETUP SHEET - HAAS FAST RESPONSE

## Job Information
| Field | Value |
|-------|-------|
| Part Number | |
| Part Name | |
| Machine | [ ] Mini Mill  [ ] Tool Room Lathe |
| Program Number | |
| Setup By | |
| Date | |
| Priority | [ ] Urgent  [ ] Standard |

## Purpose
[ ] Prototype  [ ] First Article  [ ] Repair  [ ] One-off  [ ] Prove-out

---

## MINI MILL SETUP

### Workholding
| Item | Details |
|------|---------|
| Vice/Fixture | |
| Parallels | Height: mm |
| Stop Position | |
| WCS | G54 |

### Tool List
| T# | Description | Diameter | Length | Notes |
|----|-------------|----------|--------|-------|
| T1 | | | | |
| T2 | | | | |
| T3 | | | | |

### Work Offsets
| Axis | Value | Method |
|------|-------|--------|
| X | | Edge finder |
| Y | | Edge finder |
| Z | | Tool touch |

---

## TOOL ROOM LATHE SETUP

### Workholding
| Item | Details |
|------|---------|
| Chuck | [ ] 3-jaw  [ ] Collet  [ ] Other |
| Stock | Ø x L mm |
| Stick-out | mm |

### Tool List
| T# | Description | Offset | Notes |
|----|-------------|--------|-------|
| T1 | | | |
| T2 | | | |
| T3 | | | |

---

## Notes (±0.050mm typical tolerance)

### Special Instructions:


### For Production Transfer:
Machine recommended:
Key learnings from prototype:

Setup Sheet Best Practices

Before Setup

  1. Review drawing and previous setup sheets
  2. Gather all tooling, fixtures, gages
  3. Verify program revision matches drawing
  4. Check raw material matches specification

During Setup

  1. Follow setup sheet step-by-step
  2. Document any deviations
  3. Verify tool lengths and offsets
  4. Run first part at reduced feed (50%)

After Setup

  1. First-off inspection - all critical dimensions
  2. Update setup sheet with any changes
  3. Record actual cycle time
  4. Note any issues or improvements

Continuous Improvement

  • Add "Tips" from experienced operators
  • Update tooling recommendations based on results
  • Photo key setup steps for complex jobs
  • Track setup time for benchmarking

Output Format

When generating a setup sheet, I will:

  1. Ask which machine/job if not specified
  2. Generate appropriate template
  3. Pre-fill known information
  4. Highlight fields requiring operator input
  5. Include relevant tips from tribal knowledge

Integration with Other Skills

  • PlantCapability: Verify machine selection before setup
  • AutomotiveManufacturing: Link setup sheets to work instructions
  • TribalKnowledge: Pull tips and known issues into setup sheets
Weekly Installs
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Repository
robdtaylor/personal-ai-infrastructure
First Seen
4 days ago
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