Understanding CNC Routers

First Edition

Alain Albert
FPInnovations Forintek Division
 Contents

About This Book................................................................................................1

Why Create a Book on CNC Routers?.............................................................2
Who Needs a CNC Machine?..........................................................................3
What is a CNC Router?..................................................................................4

The History of CNC.............................................................................................5

Definition . ....................................................................................................6
History...........................................................................................................6

Benefits of CNC machines...............................................................................10

The Appeal of CNC......................................................................................11
Automation............................................................................................11
Precision ..............................................................................................12
Flexibility...............................................................................................12
Limitations............................................................................................13
Embedded skill......................................................................................14
Cut Quality .................................................................................................14
Frame rigidity........................................................................................14
Accuracy ....................................................................................................15
Positioning accuracy..............................................................................15
Repeatability.........................................................................................16
Predictability.........................................................................................16
Maximizing Performance ...........................................................................17
CNC in the Media.........................................................................................18

Things To Consider .........................................................................................19

Space ..................................................................................................20
Electrical requirements..........................................................................21
Pneumatics...........................................................................................21
Vacuum.................................................................................................21

i
 Plant layout...........................................................................................22
Workflow...............................................................................................22
Inventory...............................................................................................22
Tools ....................................................................................................23
Programming.........................................................................................23
Computer network.................................................................................23
Skills.....................................................................................................24
Training.................................................................................................24
Outsourcing...........................................................................................24
Dust collection.......................................................................................24
Operator................................................................................................25
Scheduling............................................................................................25
Maintenance.........................................................................................25

The Components of a CNC Router.................................................................. 26

Controller.....................................................................................................27
Full colour display . ...............................................................................27
Program storage ..................................................................................28
Hand-held programmer ........................................................................28
Sealed air-conditioned cabinet ..............................................................28
Three-dimensional axis compensation...................................................29
Parametric design functions .................................................................29
Raw design files ...................................................................................30
Panel saw programs or Microsoft Excel files .........................................30
Profiles without custom tooling .............................................................30
Reacting to problems at the machine ....................................................31
Error reporting.......................................................................................31
Automatic tool management system .....................................................31
Preventative maintenance scheduling ...................................................32
Direct networked link to technical assistance . ......................................32
Switch between code and plain English ................................................33
Depth oscillation . .................................................................................33

ii
 Proper manuals and component labelling ..............................................33
Easy to update and upgrade ................................................................ 34
Work Tables . ............................................................................................. 34
Flat tables............................................................................................ 34
T-slot tables..........................................................................................35
Pod and rail...........................................................................................35
Universal vacuum..................................................................................36
Matrix tables.........................................................................................36
Motion.........................................................................................................37
The Cartesian coordinate system...........................................................37
Linear and rotational motion................................................................. 38
3 & 5 axis............................................................................................. 38
Rapid vs. cutting motion....................................................................... 38
Absolute vs. incremental motion ...........................................................39
Drive System...............................................................................................39
Stepper motors..................................................................................... 40
DC servo motors....................................................................................41
AC servo motor..................................................................................... 43
Spindles..................................................................................................... 44
High frequency motor spindles . ........................................................... 44
Tool Changers............................................................................................. 46
Manual................................................................................................. 46
Multiple head........................................................................................ 46
Tool holders...........................................................................................47
Automatic tool changers........................................................................47
Tooling.........................................................................................................50
High speed steel (HSS)..........................................................................50
Solid carbide.........................................................................................50
Diamond tooling....................................................................................51
Tool geometry.......................................................................................52
Tool profile............................................................................................52
Chip load...............................................................................................53

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 Cutting Parameters..................................................................................... 54
Feed speed...........................................................................................55
Climb and conventional cutting..............................................................55
Rough cutting and finish cutting........................................................... 56
Ramping and offset.............................................................................. 56
Tab and skin......................................................................................... 56
Work Holding...............................................................................................57
Manual..................................................................................................57
Vacuum.................................................................................................58
Capacity................................................................................................59
Conventional vacuum fixturing.............................................................. 60
Pod and rail.......................................................................................... 60
Combination pod/flat table.................................................................... 60
High flow vacuum................................................................................. 60
Roller hold-down...................................................................................61
Vacuum Pumps............................................................................................62
Regenerative vacuum blowers.............................................................. 63
Dry running rotary vane vacuum pumps................................................ 63
Oil recirculating rotary vane vacuum pumps.......................................... 64
Positive displacement rotary blowers.................................................... 64
Rotary claw vacuum pumps.................................................................. 65
Rotary screw vacuum pumps................................................................ 65
Liquid sealed pumps............................................................................. 65
Material Handling........................................................................................ 66
Scissor lifts.......................................................................................... 66
Vacuum lifts..........................................................................................67
Automated material handling ................................................................67

Router Configurations.................................................................................... 68
X-Y Tables....................................................................................................69
Cantilevered................................................................................................70
Moving Table...............................................................................................70

iv
 Moving Gantry.............................................................................................71
Pendulum....................................................................................................72
5-Axis.........................................................................................................72
Industrial Robot...........................................................................................73
Other Categories of CNC Equipment.............................................................74

Software..........................................................................................................75
CAD.............................................................................................................76
CAM........................................................................................................... 77
Parametric Design.......................................................................................78
Nesting Software.........................................................................................79
Post Processors...........................................................................................80
G-Code........................................................................................................80

Accessories..................................................................................................... 82
Label printing....................................................................................... 83
Optical readers..................................................................................... 83
Probes.................................................................................................. 83
Tool length sensor................................................................................ 84
Laser projectors................................................................................... 84
Vinyl cutter........................................................................................... 84
Coolant dispenser..................................................................................85
Engraver................................................................................................85
Rotating axis.........................................................................................85
Floating cutter head.............................................................................. 86
Plasma cutter....................................................................................... 86
Aggregate tools.................................................................................... 86

Justifying the Cost of CNC..............................................................................87

Light duty............................................................................................. 88
Medium duty.........................................................................................89
Industrial strength.................................................................................89

v
 Shipping............................................................................................... 90
Installation and training........................................................................ 90
The Formula......................................................................................... 90
An example...........................................................................................91

The Future....................................................................................................... 92
The New Factory.........................................................................................93
New Techniques......................................................................................... 94
New Materials.............................................................................................95

Conclusion...................................................................................................... 96

Terminology.................................................................................................... 98

Acknowledgement.........................................................................................101
In making this book.............................................................................101

References.....................................................................................................102

iv
 about this book

About This Book

Why Create a Book on CNC Routers?
Who Needs a CNC Machine?
What is a CNC Router?

1
Understanding CNC Routers

Why Create a Book on CNC Routers?

There is a lot of anecdotal information on CNC (Computer Numerical
Control) technology and machine vendors are often quick to highlight
certain features of their products while minimizing other very
important characteristics.

The truth is that in every case the purchaser must make

compromises to come up with the solution that best fits their needs.
Not one application is exactly the same and not one machine will be
the perfect fit in every shop.

This book was created to give potential consumers of CNC routers a

basic understanding of the inner workings of the technology. A better
informed consumer can then make better purchasing decisions and
increase the chance of successful integration of the technology in his
or her shop.

2
 about this book

Who Needs a CNC Machine?

What does a CNC do? Will it replace workers? Is my job in jeopardy?

These are some of the questions you will face from your employees
when you are thinking of buying a CNC machine.

While it will probably replace tedious repetitive jobs with higher

skilled ones, most companies who purchase this technology end up
growing and hiring more employees.

The work that happens downstream from the CNC machine will also
be impacted. The parts are likely to be more accurate and in the
case of nested based systems, they will remain grouped together,
simplifying subsequent processes.

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Understanding CNC Routers

What is a CNC Router?

In short, CNC technology is not very complicated. It is a tool
controlled by a computer. It only becomes more sophisticated when
considering how the computer controls the tool. The illustration
below shows what a bare bones CNC machine might look like minus
the controller.

4
 The history of cnc

The History of CNC

Definition
History

5
Understanding CNC Routers

Definition
CNC = Computer Numerical Control. A computer controller reads
G-code or machine language instructions and drives a tool.

The NC (Numerical control) program is a detailed set of step by step

instructions that tell the machine which path to follow and which
operations to perform.

History
NC or simply Numerical Control was developed in the late 1940s
and early 1950s by John T. Parsons in collaboration with MIT
(Massachusetts Institute of Technology). It was developed to help
in the post war manufacturing effort. Aircraft parts were becoming
more complex and required a level of precision that human operators
could not achieve.

Complex machined parts could no

longer be made by skilled operator
alone
Photo courtesy of CNC Software Mastercam

6
 The history of cnc

At first machines were hardwired, and then instructions were given

via punched tape starting in 1952. Five years later, NC machines were
being installed in metal working production environments all over
the United States. By the mid 1960s, NC technology was playing a
dominant role in the industry.

Most machine programs were recorded on a punched paper or

aluminium tape until about 1980. In the 1970s and 80s, the growth
of microprocessor technology made it possible for computers to be
connected directly to NC machines using cables, hence the term
CNC.

Fundamentally, numerical control is a technique for controlling

machinery rather than a specific type of machine. CNC machines
were originally built for machining metal. They were subsequently
adapted for other industries such as wood, fabric, foam, and plastics
to name just a few. All these machines have some features in
common which are:
a program (instructions)
a controller
a machine tool.

Wood routers differ from their metalworking cousins in that they are
not subjected to the same forces of load and vibration. They spin
faster, up to 24000 rpm and have larger work tables; up to 5'x20'.
They use smaller tools and tool holders and work at faster machining
speeds; up to 1200 inches per minute or 30 m/min. Another
difference is that they dont require the same level of accuracy.
Metalworking applications usually require much greater precision and
tighter tolerances than for machining wood.

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Understanding CNC Routers

Mr. Isao Shoda claims to have made the first NC Router in the world
and he exhibited it at the International Osaka Fair in 1968. (Model:
NC-111A)

1968 Shoda exhibited the first ever

NC wood router (NC-111A ) at the
International Osaka Fair
Photo courtesy of Shoda Iron Works Co. Ltd.

Early in the 1970s the advent of the first CNC appeared in the
aerospace industry (controlled by a Mainframe Computer).

In the late 70s NC drilling machines were the first to appear in the
wood industry. They were called point-to-point machines because
they moved a drill from one point to another and drilled a hole. The
term point-to-point was coined from an electronics circuit assembly
method from pre-1950 which required professional electronic
assemblers to operate from books of photographs, and follow an
exact assembly sequence to ensure that they did not miss any
components.:

Other events that impacted CNC technology were:

Mid-1970: first microprocessor (Intel 8080)
End of the 1970s: First 5 axis CNC in woodworking.

CNC routers were first used by the aerospace industry to cut

complex patterns out of sheets of aluminium. Bolting the aluminium
sheet to the table surface was a lengthy process. In the early 80s, the

8
 The history of cnc

engineers at Thermwood came up with the idea to draw air through

huge butcher blocks made of Balsa wood. Since Balsa wood lets air
pass freely through the end grain, they added a high flow vacuum
to hold the aluminium sheets down without the use of mechanical
fasteners. They later realized that particleboard had similar porous
properties and universal vacuum tables were born.

By the early 1980s, CNC technology was used in many types of

machinery in the secondary woodworking industry. Some examples
follow:

Point-to-point systems such as boring machines have been used

since the beginning of the NC era. Since there was no contact
between the part and the tool until a pneumatic drill was activated,
it mattered little which path the spindle took to reach its final
destination, hence the term point-to-point. These machines were
later adapted to the newer CNC technology and although they
incorporated more options than just drilling, the name persisted.

Straight cutting systems such as NC panel saws confine the

control to only one single axis of motion. The saw blade then travels
independently from the control across the length of the beam to
perform a straight cut.

Contour cutting such as that seen in CNC work centers allows for
the simultaneous motion control of 3 or more axes while performing
machining operations. In other words, the computer controls the
cutter in space along the x, y and z axes while performing the cut.

Today CNC machines are a ubiquitous part of the manufacturing

process. New functionality and improved performance is being
developed every day which will give CNC an ever increasing role in
the success of our industry.