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This is a large page with many pictures and much information please be patient.
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Shaped router cutters are a very effective way of detailing wood without the use of a 3D package the tool will follow any line draw in 2D design that is as thick as the cutter. Thus it is easy to make a patterned edge by just altering the line width to one of your defined ogee or ovolo router bits and select a unique colour that you match to your tool when passing to mill. This method is also very fast too, particularly if you have a large class of kids queuing up. Cutters can be used in a number of ways, Trenching, Profiling or grooving. Some very good effects can be produced simply in drawing terms and quickly in manufacturing terms. With handheld router now outlawed in schools it has become as quick to furnish the CAD/CAm system with these tools than the time it takes to set up a static routing station. The results are more accurate and infinitely repeatable.
It is a good practice to radius corners as this reduces the tendencies for the wood to splinter as the Ovolo cutter runs round the edge. |
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Boxford can supply a set of 12 router cutters under part number TO-RTR-BIT-KIT.
This kit has some very useful and exciting cutter profiles that can solve a number of problems, By their nature they need a little care and attention during their use. The Boxford machines support the alterations in the cutting speeds and machining procedures necessary to use these specialist cutters. |
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Tool 1. Two flute cutter 7.9mm diameter
The 8mm cutter can be used for a number of tasks including machining flat faces groves, mortises and tenons. The round nature of the tool has to be taken into consideration when using to make a joint. I.e. If the wood can be presented vertically i e the side is below 106mm in length then the joints can be cut without worrying about the corners. If however a long side is to be cut with the wood held flat in the vice then the cutter will leave a half round end. To ensure a snug fit the radius must be cut on the short side that is presented vertically.
The machining file would look like this, 8mm thick lines with 8mm gaps. The radius at the end to machine the pegs to fit the slots.
Cutting of half rounded pins to match horizontal cuts.
Cutting of end fingers on alongside.
Close Up Of Joint
This could be the basis of any number of small box projects.
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Tool 2. Dovetail cutter angle=104 degrees 12.7mm diameter
When cutting a dovetail it is important to control the cuter movement, the cutter must plunge to full cutting depth off the work then move in to and across the work never breaking the path until it finishes again off the job. The feed rate for all materials has to be dropped in the tools menu i chose a feed rate of 100 do this job which was a little slow but was forgiving to the tool should i make a mistake. When cutting with a dovetail cutter if the pieces are to match and keep the math simple then the centre of the cutter must run through the centre of the wood, in the Boxford kit the centre of the cutter is 9.5mm wide and this to make good fitting joints the cuts should be 19mm apart 9.5 x 2. Once again the round nature of the cutting tool means that the vertical cuts need to be rounded out. Cutting Path.
Cutting the rounded end pieces in a vice with two 10 x 30mm bar extensions to allow the wood to rest on the bed. This will allow up to approx. 105mm sides. If the vice was rotated by 90 degrees and the wood dropped into a t slot this would extend the maximum to 120. For educational applications 120 mm sides should be adequate for most class projects.
Cutting the side dovetails using the step milled into the vice jaws.
Close up of the dovetail joint. Note how in one direction the joint has had to be rounded to fit the shape made on the other piece by the action of the cutter.
The finished example.
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Tool 3. Keyhole Slotter
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Tool 4. Rounding over 4.8mm radius x 12.7mm cut |
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Tool 5. Ogee panel 2mm radius
Worked example.
It is a good practice to radius corners as this reduces the tendencies for the wood to splinter as the Ovolo cutter runs round the edge. Full depth profile (5mm) cutter running on edge of shape Radius cutting corners helps to reduce chipping.
It is a good practice to radius corners as this reduces the tendencies for the wood to splinter as the Ovolo cutter runs round the edge. Partial depth profile (3mm) cutter running on contour line 4mm from edge of shape Radius cutting corners helps to reduce chipping.
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Tool 6. Rounding over 9.5mm radius x 22.2mm cut
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Tool 7. Radius 6.3mm radius x 12.7mm diameter
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Tool 8. Radius 2.4mm radius x 4.8mm diameter
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Tool 9. Chamfer V groove cutter angle=60 degrees
Although the grove cutter may seem to have relatively limited applications once you place it in the hands of a CNC machine the possibilities are enhanced multifold. A very effective use is in the production of carved signs this can be done in a number of ways in relief form with the letters raised in woodcut form with the letters cut below the surface or a combination of the two.
Initially the red area was machined out using a 3mm cutter to 5mm deep, this gave a flat base and partially profiled the letters. The the Blue line was thickened to 12.7 mm and run round at a depth of 2.5mm with the 60 degree cutter to give the carved effect.
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Tool 10. Chamfer 45 degrees x 12.7mm diameter
Again in the hands of a CNC router this cutter can be used to make far more that just chamfers. Its vertical cutting blades mean that it can also do quite deep trenching work a simple ball bearing maze was made to show the depth of cut that can easily be achieved.
The V shaped tracks make the junctions very jumpy and the ball sticks, this would make a well designed maze where the path is made of mostly T junctions very hard as the ball accelerates and shoots past the entrance you are trying for.
Vacuum formed lid to retain the ball.
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Tool 11. Ovolo 3.2mm radius x 9.5mm diameter
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Tool 12. Two flute cutter 4mm diameter
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