Fadal Mill

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Commonly Used Fadal Machine Commands

CS	Cold Start	Run on startup after jogging axes to +-0.2000” of their home positions
HO	Home	Returns machine to its home position
SETTO	Set Turret Order	Defines the currently loaded tool as Tool #1
TC,1	Tool Change	Opens the tool changer (can also use T1M6 in G-Code to load tool #1)
DF	Display Fixtures	Display the fixture offset table
> 1	New Value	Overwrites an existing offset
> 2	Modify Value	Shifts an offset by a specified amount
> 3	Utilities	Contains useful functions for computing fixture offsets
DT	Display Tools	Displays the tool offset table
> 1	New Value	Overwrites an existing offset
> 2	Modify Value	Shifts an offset by a specified amount
> 3	Mass Modify	Shifts a group of tools by a specified amount
> 4	Utilities	Launches the tool setting cycle
CD,10	Change Device	Allows communication over the USB port
> DIR+		Lists the directory of a connected USB Flashdrive
> TA,NAME.NC+		Loads the program “NAME.NC” onto the machine
PR	Program Maint.	Change the actively loaded program
PA	Program Access	Displays the actively loaded program, and allows for Modifications
> G	Graphics	Use the Autodraw to visualize the toolpath
MU	Menu	Displays a list of all the Fadal machine commands
UT	Menu	Displays a list of all the Fadal offset utility options
> 1	Tool Setting Cycle	Displays tool setting options
> 2	Fixture Setting Cycle	Displays fixture setting options
> 3	Test TS-20 Probe
> 4	Test MP1, MP8 Probe
> 5	Pallet Change	Displays a pallet change menu
> 6	Clocks	Displays clock setting options
> 7	Exit	Exits the offset utility options page

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Fadal Mill Operation Guide

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G & M Codes

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General Operation

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Mill Setting Tool and Work Offsets Practical

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Rigid Tapping Basics

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Avoid Chatter on the Mill

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ER Collet Torque Chart	Double Angle Collet Torque Chart

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Tap Breakage Troubleshooting

Program Troubleshooting

• The RPM may be too high:
  • Set the RPM to a maximum of 2000, or 150 inches per minute feed, whichever comes first.
• If you are using a tension-compression holder:
  • Use 90% of the actual feed calculated for the thread to allow constant pressure on the tap as it enters and exits the hole.
  • Use 90% of the actual feed calculated for the thread if the machine does not have the Rigid Tap option.
• Check the feedrate:
  • The speed and feedrate must be precise to maintain the correct synchronization between the tool and the Z-axis.
• Keep the R-plane no shorter than 0.200” ( 5 mm) to give the machine some space to synchronize and accelerate.
• If tapping small holes:
  • Put the machine to high gear (M42).
  • Tapping small holes in high gear speeds up the tapping process.
  • The high gear has less mass in the drive train to start and stop.

Tap Troubleshooting

• Spiral flute taps:
  • Spiral flute taps are designed to pull chips out of the hole and away from the cutting area.
  • They work well when tapping a blind hole.
• Spiral point taps:
  • Spiral point taps are designed to push chips forward and into the hole away from the cutting area.
  • They work well when tapping a through hole.
  • They do not work well in blind holes because the tapping chips can pack into the bottom of the hole and cause the tap to bottom.
• Tap run out:
  • Make sure the run out is correct for the tap.
  • Some taps break if the TIR is more than 0.001" (.03 mm).
• Make sure the tap is designed for use on CNC equipment:
  • Spiral flute taps work well and will eject chips from the working area.
  • Roll taps are stronger than cut taps and are recommended for small diameter tapping.
  • Hand taps are not designed for use on CNC machines.
• Check the tap holding:
  • If the tap holder is a collet, make sure the tap does not slip.
  • If the tap holder is a collet, make sure the tap is not running out.
  • Taps must be held with a positive-drive device.
  • Make sure the collet is specifically designed to hold taps.

Material Troubleshooting

• Hard Materials:
  • If the material is very hard, do not use coolant.
  • Clear the chips out of the holes and use a cutting fluid.
• Soft Materials:
  • Soft, gummy materials require a consistent cooling mix.
  • They may also require special tapping compounds.
  • Check the coolant concentrations with a refractometer.
  • Always follow the manufacturer's mixing directions or use tapping solutions.

Hole Troubleshooting

• Check the hole depth:
  • Blind holes need be drilled at least 0.050” deeper than the tap is programmed to go.
  • The hole will be shallower than what is programmed because of the tip angle on the drill.
  • Setting an offset for the tip of the tool will make the hole shallow by the amount lost by the tip angle.
  • The program can compensate for this by drilling slightly deeper. This gives you the diameter required to the depth required.
• Spot drill, then tap:
  • Spot drill a pilot hole before tapping.
  • This will insure that the drill is located accurately.
  • Drill the pilot hole slightly greater than the major diameter of the tap size.
• Make sure the tap drill is the correct size:
  • For 75% of effective thread use this formula:
    • D - 1/N
    • D = major diameter of the tap
    • N = number of threads per inch
• Hole dimensions:
  • A tapped hole with 75% of thread depth has only 5% less strength than 100% thread and takes only 1/3 of the cutting force of a 100% thread.
  • One and one half times the major diameter is the usual depth requirement for a tapped hole.
  • The strength of a threaded connection does not increase if the contact length is more than 1.5 times the diameter of the fastener.
  • Chances of breaking the tap increase dramatically when tapping more than one-and-a-half times the major diameter

Machine Troubleshooting

• Z Axis Overshoot and Drift:
  • Use an indicator and a simple, repeating incremental tapping program to test drift.
  • If the Z-Axis overshoots/drifts farther than what is programmed in the G84:
    • Notify shop staff.

Coolant Troubleshooting

• Tapping Compound:
  • If coolant may be the cause of the problem, program a series of holes and brush a tapping compound or tapping oil on the tap instead of coolant.
  • Tap Magic makes several different types of high quality tapping fluid.
• Coolant Condition:
  • Always follow the coolant manufacturer's recommendations for mixing coolant.
  • Check the coolant concentrations with a refractometer.
  • Make sure the water has a low mineral content. Minerals in the water break down the quality of the coolant and reduce the coolant's effectiveness.

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Various Fadal Mill Information and HSMWorks Post Processors

• Please click here for other various Fadal Mill information and HSMWorks Post Processors.
• Please click here for other Fadal resources.

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