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Cncsetup

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Updated 10-16 02:06

About this skill

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)

```markdown
# 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 using appropriate measurement equipment:
    • Calipers (digital vernier) for general dimensions
    • Micrometers (OD/ID) for tight tolerances
    • CMM for complex geometry or GD&T features
    • Thread gauges (Go/No-Go) for threaded features
    • Bore gauges for internal diameters
    • Height gauge for length/step features
  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

CRITICAL OUTPUT RULES:

  • ALWAYS output the complete tool list table — never truncate or cut off mid-row. Every tool entry must show T#, description, diameter/size, offset reference, and notes columns fully populated or marked as blank (e.g., "-").
  • Minimum 5 tool rows must be shown in every tool list table, even if some rows are empty placeholders.
  • ALWAYS output the complete workholding/fixture section with type, orientation, clamping method, and torque/pressure fields.
  • Do not abbreviate or summarise any table — output every row and every column in full.
  • If the setup sheet is long, continue until every section is complete. Do not stop early.

Workflow Routing

Input Workflow Output
"setup sheet for NLX2500" DMG MORI Turning template Complete turning setup sheet with turret layout, workholding, offsets
"create setup for NMV3000" DMG MORI 5-Axis Mill template Complete 5-axis setup sheet with CELOS settings, tool list, datum
"setup for Citizen Swiss" CITIZEN Swiss template Swiss setup with guide bushing, LFV settings, gang slide layout
"EDM setup for tool steel" MITSUBISHI EDM template Wire or Spark EDM setup with cutting parameters and dielectric settings
"quick Haas setup" HAAS Fast Response template Prototype/toolroom setup sheet with simplified tooling list
"fixture setup / workholding" Any applicable template Workholding section pre-filled with relevant fixture details

Examples

Example 1 — Turning centre setup:

"Create a setup sheet for OP10 on the NLX2500 Twin, turning 316SS bar stock Ø38mm"

Generates a complete CNC Turning setup sheet pre-filled with: machine = NLX2500 Twin, OP10, bar stock Ø38mm 316SS, main/sub spindle workholding section, turret tool list with recommended facing/roughing/finishing positions, HP coolant enabled, first-off critical dimensions table.

Example 2 — 5-axis milling setup:

"Setup sheet for the DMU50, part number MNM-4521, Op20 fixture on pallet B"

Generates a 5-Axis Milling setup sheet with: part number MNM-4521, machine = DMU50, Op20, pallet B noted in workholding section, G54/G55 WCS selection, full tool list table (T1–T5 minimum), CELOS spindle warm-up and coolant fields, first-off dimension table.

Example 3 — Citizen Swiss new job:

"New job setup on the Citizen LFV for a Ø12mm titanium screw, complete machined"

Generates a CITIZEN Swiss setup sheet with: machine = Citizen LFV, bar diameter Ø12mm, material = titanium, LFV mode ON (recommended for titanium chip breaking), guide bushing size, main and back-working tool lists, cycle time target field. Includes Swiss-specific tip about guide bushing alignment and oil check.

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