Cuttermasters CM-01P Bedienungsanleitung
The CUTTERMASTER Professional
CM-01P
Operator’s Manual
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CUTTERMASTER Professional CM-01P User’s Manual
Page 2
Table of Contents
Chapter 1 The CUTTERMASTER Professional CM-01P
1.0 Introduction, Forward, Contact Information .......................... 3
1.1 Disclaimer............................................................................. 4
Health Warning: Dust ........................................................... 4
1.2 Specications ....................................................................... 5
Theory Behind the CM-01P.................................................. 6
1.3 Set Up................................................................................... 7
1.4 Care for Your Machine.......................................................... 9
Chapter 2 The Basics
2.1 EndMillDenition............................................................... 10
Types of Relief.................................................................... 10
Test Tools.............................................................................11
2.2 Organizing Your Grinding Project ........................................11
Edges,MaterialandProles............................................... 12
General Approach............................................................... 12
2.3 Typical Wheels ................................................................... 13
Grinding Wheel Truing & Dressing ..................................... 13
Chapter 3 Operations
3.1 Flute OD Grind ................................................................... 16
3.2 End Mill End Grinding 11V9 Wheel .................................... 19
3.3 End Gashing....................................................................... 20
3.4 Flute Inside Grinding (gumming out) .................................. 20
3.5 End Mill End Grinding 1A1 Wheel and Center Cutting....... 20
3.6 Neck Reduction Grinds....................................................... 22
3.7 Radius Grinding Basic Set Up............................................ 23
3.8 Bull Nose End Mill Radius Grinding.................................... 24
3.9 Ball Nose End Mill Radius Grinding.................................... 27
3.10 Clearance Radius Angle Grinding ...................................... 29
Appendix KB Control Board Manual ............................................................. 31
Appendix Training Videos ............................................................................. 31
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CUTTERMASTER Professional CM-01P User’s Manual
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Copyright 2017
Toycen This document may not be reproduced in whole or in part without the express written permis-
sion of Toycen Industries
Cuttermasters
2353 Ridgecrest Place
Ottawa ON K1H7V4
Canada
(800) 417-2171
info@cuttermasters.com
Toycen Corporation
808 Proctor Avenue
Ogdensburg NY 13669
U.S.A
(800) 417-2171
info@cuttermasters.com
Section 1.0: Introduction
Congratulations on purchasing your CUTTERMASTER Professional CM-01P.
The CUTTERMASTER has been the best name in bench top end mill sharpeners since 1972 and
that tradition of quality continues with the new professional version. The Cuttermaster Professional
CM-01P has been designed with new features to meet the demands of today’s prototype and pro-
ductionshopsandprovidessuperiorexibilityandeaseofusefortoolregrindingandtoolmodica-
tions.
With the CM-01P you will be able to grind the diameters and ends of standard end mills in one easy
setup. With nine working axes you will also be able to sharpen roughing end mills, reamers (circum-
ferential lands), end gashes, side and face cutters, annular drills, and countersinks. You will be able
togrindreducednecks,cylindergrindsmallrounds,grindWeldonats,andcut-offcarbideorhigh
speed steel tools.
This revolutionary product was designed and built in our own shop. If you have any questions about
this or any of our productool spindle feel free to contact us.
Forward
Contact Info
If you have any service or partool spindle requests, or questions or commentool spindle about this manual,
please feel free to call or write to us at
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CUTTERMASTER Professional CM-01P User’s Manual
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Chapter One
The CUTTERMASTER Professional CM-01P
Set up and General Information
1.1 Disclaimer
The CUTTERMASTER Professional is a machine tool and as such is heavy and has large moving
partool spindle and grinding wheels rotating at high speed. These wheels are dangerous and they
emit dust, carbide and steel fragmentool spindle during the normal course of operation which are
harmful if inhaled or come into contact with skin or eyes. The manufacturer is not responsible for any
injury or death caused by this apparatus.
Upon delivery the owner of the machine assumes full responsibility for itool spindle safe operation.
Care must be taken to observe proper industrial safety precautions. Always wear suitable breathing
and eye protection when using the CUTTERMASTER Professional or any other grinding machine.
Health Warning: Dust
Tool grinding and grinding in general produces dust that is hazardous to your health and may con-
tain heavy metals. We strongly urge that you consider a dust exhaust system. You are responsible
for taking the proper precautions and/or utilizing the proper auxiliary exhaust systems to protect your
health and that of your employees.
Toycen Industries, by this advisement waives any and all responsibility for any real or alleged claims
of health damage as the result of using their equipment(s) without heed to this warning.
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CUTTERMASTER Professional CM-01P User’s Manual
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1.2 Specications
Imp. Graduations: 0.001
Air Bearing Stroke: 8.5” (266mm)
Air Bearing: Standard 5C Collet
CuttingToolCapacity: 2”shank,9.8”O.D.,8.5”utelengthT-slotdimension–.800x.500x.670
Table feed graduations: 0.0005 x axis carrier travel, 9” plus manual adjustment of 6”
x Axis working space: 26.5” x5 .5”
y Axis working space: 13” x 6.5”
z Axis carrier travel: 5”
Wheel Mounts: 1¼ Wheel Mounting Hubs for standard tool grinder wheels with a 1.25”
arbor.
Wheel Hubs Separate to the motor so that custom wheel hubs can be installed if
needed.
Motortilt: Innite
Motor: 500 Watt DC Reversing and Variable Speed
Warranty: Two Year on Motor and Control
Net weight: 225 pounds (100 kg)
Dimensions: 31 X “ x 27 Y” x 21” (not including handles) Shipping dimensions - 36” x
33” x 29”
Overview
The CUTTERMASTER Professional has been designed to accommodate a variety of needs. The
tableisalargestableatsurfacewithcarriagedriveunderneath.
This system has been designed to be easy to use and maintain. As with all machine tools care must
be taken to keep all working surfaces clean and in good repair. There are four main components to
your CUTTERMASTER Professional:
• the CUTTERMASTER Professional CM-01P Universal Base
• the Toycen Radius Air Spindle and assembly
• theToycenInniteTwinSpindleDCMotorTowerandassembly
• the DC control
The tower and tool spindle carriages can be removed, cleaned and reinstalled very easily with the
removal of the drive bolts.
Thetoolrestisacentraltothemachinepivotandisextremelyeasytouse.Theairbearingxtures
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are precision honed and capable of grinding to close tolerances. The spindle sleeve is made from
stainless steel and the spindle itself is chrome plated steel.
The Toycen Radius Air Bearing has a 180° swivel base for radius grinding and takes standard 5C
colletool spindle with end mill holders available that can hold shank sizes up to 2”. The Toycen In-
niteTwinMotorTowerprovideseasyandaccuratepositioningofthewheelstothetoolbeingground
and allows two wheels to be set and trued allowing for the indexing of one wheel to the next which is
intended to reduce set up times. The table is cast, aged monolithic grey iron.
The DC Motor comes standard with two spindles so motor/spindle assembly tilt to positive and nega-
tive angles and rotates 360°. Cutting tool clearance angles can be adjusted as needed providing real
angle result when setting angles.
There are 9 different axes to work with for unlimited versatility. Your CM-01P grinds O.D.s (outside
diamters)andendsofstandardendmillsinonesetupwithinafewminutes.insideutes,ends
(primary and secondary), as well as roughing end mills, carbide tools, reamers, end gashes, small
roundsorreamers(circumferentiallands),reducedneckgrinds,Weldonats,carbideandHSScut
off.
Theory Behind the CM-01P DC Tower
TheoriginalCUTTERMASTERwasdesignedin1972whentheprevailingendmillswerelongerute,
HighSpeedSteel(HSS),30degreehelix,ballnose2,4,and6ute.Todayweseedifferentgeome-
tries,widespreaduseofcarbide,smallcornerradii,reducednecks,andcuttermodicationsaremore
prevalent. HSS tools can be ground until the geometry won’t run any longer and this is not the case
with carbide. Carbide fails over time or with heat, whereas steel gets dull. This being said, cutting off
and grinding ends and corner radiuses has become more important.
Most grinders have a single speed AC motor, designed to be inexpensive for the manufacturers to
produce. This is not conducive to a good tool grinding environment where conditions vary from tool to
tool. DC motors have more torque throughout their variable range of speeds allowing for deeper cuts
without heat damage to the tool, given that it is a dry grinding environment. The twin wheel head of
theCM-01PDCTowercanbeipped,reversedandspeedadjustedtosuitmostanygrindingrequire-
ment.
Onthetopicofwheels,ourwheelshavebeenspecicallydesignedfordrygrindingandgoodbal-
ance. Once you get your wheels dialed in, you can work from wheel to wheel without having to re-
mount and dial in as frequently.
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CUTTERMASTER Professional CM-01P User’s Manual
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1.3 Set Up
CUTTERMASTER Professional Packing.
The feet of the CM-01P are shipped separately, install them and level the machine before use.
Important,
Tables should move freely with the handwheels.
Toycen Universal Tower Details
The Universal DC Tower is reversible, variable speed and produces ten times the torque than the
standard 1/3 HP motor (5 Foot Pounds @ 1000 rpm). This eliminates tool burning by facilitating heavy
cuts at greatly reduced RPM, cutting grinding times in half on some tools.
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CUTTERMASTER Professional CM-01P User’s Manual
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The CUTTERMASTER Professional has been designed using the proven Cuttermaster Machine
base, the system is stable and allows for the use of magnetic base indicators in virtually any position.
There is no guessing when dialing-in any feed or position move. Being made from a monolithic cast
baseandmotortower,theCM-01Pabsorbsvibration.Havingsignicantmassalsomeansthatifad-
justmentsare“snug”,motorrotationandtowerpivotcanbeusedwithoutsignicanttightening.
Choose a good stable and quiet location for the machine. The CUTTERMASTER Professional is very
quiet.Levelthemachineusingalevelonthewaysandnetunewiththeadjustablefeet.
Wipe any oil off of the ways. They should be clean and dry for operation. They may be wiped down
from time to time with a WD-40 and oil mix to prevent rust.
During normal operation care should be taken to keep the carriages and leadscrews clean and free
from dust and can be done with air. The lead screws are black oxide 4140 steel with steel drive nuts.
The carriage drive nutool spindle can be easily replaced should they wear over time.
A light colored back drop helps the operator locate the grinding wheel as it approaches the tool and
also protectool spindle the ways.
Check the air spindle components and wipe them completely free from dust and oil using acetone or
a solvent that does not leave a residue. Apply air and slide the air spindle tube into the bushing on the
assembly.
Put the lock ring on the front and slide the indexing collar over the back.
Note: Always have air supplied to the air spindle when being moved or in use.
All of the tool spindle pivot cap screws are intended to be used to tension the pivot action and sta-
bility of the tool spindle mount. Any of these screws can be used to lock the rotation when required
onoperationssuchasuteendsorradialgrinds(O.D.s)andoneofthesescrewsispaintedredfor
your convenience. The pivot should be able to be locked by tightening only one screw while the other
three are snug.
Hook up shop air to the air spindle with the coiled hose provided. There must be clean dry air present
(musthaveanaiddryerontheline)itcanbeusedwithoutadditionalltrationandmoisturecontrol.
Theairspindleusesonetotwocfmat80to100psi.Aregulatorlterhasnotbeenshippedwiththe
machinewhichcanbemountednearthemachineifrequired.Thelterassemblyisnotattachedto
the air spindle because there are adjustment devices that need to be accessed and the spindle must
be free to move.
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CUTTERMASTER Professional CM-01P User’s Manual
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Free up the power cables and check them for damage. Read the appendix KB Control Board Manual
before operating. The internal circuit board trim pots have been set according to our preferences.
Note: Always check all wheel mounts, angular and rotational adjustmentool spindle for suit-
able tightness prior performing a grinding operation.
1.4 Care for your Machine
Themachineshouldbekeptfreeofdustanddebrisandwhennotinusealightlmofoil(e.g.WD-
40) should be applied to unprotected metal surfaces.
The assemblies are all steel and the threads should be kept clean and dry: a periodic cleaning by
spraying with WD-40 and then blown off with compressed air will keep the lead screws in good ser-
vice. Gibs should be free of dirt and slide freely.
Using the Tool Rest Assembly
The tool rest assembly is secured from stowed position to working position using the two thumb
screwsshownintherstimage.Besurethattheatfaceonthetoolrestbariscorrectlyaligned
to register with the ends of the set screws. When the tool rest is in stowed it is best snug but not to
tighten the thumbscrews. This preventool spindle marring the bar.
Tool Rest in Park Position
Tool Rest in Working Position
Tool Rest Thumb
Screws
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CUTTERMASTER Professional CM-01P User’s Manual
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Chapter Two
The Basics
2.1 End Mill Denition
Endmillsareprolesharpmillingcutters.Assuch,theyrequirecertaintreatmentwhensharpening.
These tools have a relatively small diameter in proportion to their length. Because of this long shape,
careshouldbetakenwhenholdingtoeliminatechatter,improvenishpropertiesandallowforgood
tool uniformity on the diameter. These tools also have a relatively small mass, meaning that care
should be taken by monitoring heat generated during the grinding process.
If the end mill has centers, these can be used for concentric holding. If not, the tool is generally held
byacolletattheshankendwithatoothrestsetinaspecicrelationtothewheelandtoolcenter.
This tooth/tool rest is usually placed directly at the point of contact between the wheel and the cutter,
minimizing vibration during the grinding process.
Types of Relief
End mills can be sharpened with three different types of relief on the diameter:
• aconcave,almostatsurfaceisproducedwiththefaceofaplainwheel;
• aatreliefsurfaceisproducedwithacupwheel.
• a radial or eccentric relief is produced by presenting the face of a plain wheel at an
angletothecuttingaxisofahelical-utedendmillorbydressinganangleontheface
of a wheel rotating on a parallel axis.
Eccentricreliefproducesarelativelynecuttingedgefreefromminutenicksandasaresultisstron-
gerthanthoseproducedbyothermethods.Anotherbenetofthismethodofre-grindingisthata
secondary clearance is not needed. If the grinding wheel face width is maintained so that it is wider
than the relieved land (measured in an axial direction), wide primary lands are possible without dan-
geroftheheelofthelandcontactingthenishedsurfaceproducedwhentheendmilliscutting.This
is due to the fact that the clearance angle formed by the curve or angle on the wheel increases as it
progresses further from the cutting edge. Most manufacturers, however, consider it good practice to
provide a secondary clearance on end mill teeth, except on the smallest size of cutters.
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