Multicam Systems Pty A2MC Installation guide

A2MC Machine
Installation and
Training
Documentation
Revised 9 February, 2017© Multicam Systems Pty Ltd
All rights reserved. No part of this document may be reproduce or transmitted in any form or
by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior
written permission of Multicam Systems Pty Ltd.

Machine Component Identification
The following diagram and table indicates the location of major components of the machine. There
may be variations depending on individual size, configuration and options fitted.
Item Description Items marked * are optional and may not be present on all machines
1 Machine bed. Aluminium vacuum hold down table or t-slot table
2 Travelling steel gantry. Contains X axis drives
3 Machine head. Contains Y and Z axis drives
4 Travelling rotary tool changer*
5 Location of cutting spindle/s*, knife head/s*, camera*
5 Location of Air assist head attachment*
6 Operator’s sub console unit
7 Mist sprayer attachment*
8 Inverter enclosure - Danger High Voltage
9 A2MC controller enclosure - Danger High Voltage
10 Micro air filter inlet and distribution
11 Power Box Master On/Off control for machine - Danger High Voltage
12 Machine frame
13 Linear tool changer*
14 Machine air supply, tool change and vacuum pressure gauges*
15 Additional switches for dust collectors, vacuum pumps, other ancillary devices*
16 Emergency stop buttons, operator’s and off side of gantry

HEALTH AND SAFETY
General Safety And Machine Specifications
This manual and the safety guidelines contained within it are designed to enable the user to
obtain the best performance from the machine over a long lifetime and to ensure the safety
of the operator. Each person who will operate the equipment, perform a service or
maintenance, or supervise its use must read the safety instructions in this manual. Please
read it carefully before using or working on the machine.
The machine is a 3-axis router designed to cut and shape a variety of materials using either
vacuum or manual clamping. The correct method of using these mechanisms is covered
elsewhere in the users manual.
Ensure that you have read and understood the operational and health and safety sections of
the manual before beginning to use the machine.
The machine has been designed and constructed to prevent the build-up of electrostatic
charges during operation.
The machine is not intended for use in an explosive environment.
ALWAYS CONSULT SEPARATE MANUALS FOR ANCILLARY
DEVICES SUCH AS MIST SPRAYER ATTACHMENTS, OSCILLATING
TANGENTIAL KNIFE HEADS AND GANG DRILL HEADS FOR SAFE
OPERATION.
Placement of the Machine and machine attachments
The machine must be placed with consideration given to the following;
• The actual floor space required by the machine and associated accessories and
attachments.
• Adequate free air flow around vacuum pumps to reduce the risk of overheating.
• How you intend to move material to and from the cutting surface.
• OH&S requirements in relation to safe work practices. Refer to AS4024 & AS1473 for
specific details in regards to placement of machinery. We recommend a minimum of
1meter of space around the machine. The amount of space left behind a machine,
especially when placed in close proximity to a wall, must be sufficient so that workers,
and our technicians can have safe and unobstructed access to allow for service and
maintenance.
WARNING
Machine must only be operated by
persons trained and accredited by
Multicam Systems

General Requirements
Noise Emission
The noise level produced by the machine will be dependant on;
• the material being cut
• ancillary devices being used (knife heads, drill heads etc)
• attachments to the machine (vacuum pumps, dust collectors, air compressors etc)
• the individual workplace environment.
The appropriate health and safety regulations must be consulted when considering the location
of the machine in the workplace, any sound-proofing or acoustic enclosure to be erected, or the
provision of personal protective equipment (PPE) in the form of hearing protection.
A noise survey and specific risk assessments should be undertaken by a competent person in
each workplace and for each work situation and material being cut, but in general the noise
levels produced by the machine may be found to be in the region of the following readings:
Equivalent continuous A-weighted sound pressure level, LAEQ above 90dB (A) when machining
aluminium.
Equivalent continuous A-weighted sound pressure level, LAEQ above 90dB (A) when machining
medium density fibreboard (MDF).
There is not normally any impulsive noise from the machine.
It is recommended that precautions are taken against injury to machine operators and others
from long-term exposure to noise, either by:
• enclosing the machine in an acoustic enclosure or booth fitted with closing doors
• requiring the operator, and other persons working or having cause to be nearby, to wear
a suitable form of hearing protection.
Suitable mandatory hearing protection signs should be displayed on or adjacent to the acoustic
enclosure or in the zone where the machine is located. The wearing of adequate protective
equipment should be enforced.
Operating Temperatures
The machines are designed to be operated between temperatures of -5oC and +40oC.
During operation machine components such as spindles, vacuum pumps and cutting tools will
become hot. Care must me exercised when coming in to contact with these or any other items
likely to become affected by heat.
Vacuum Pumps:
Vacuum pumps expel hot air at high velocity. Adequate provision must be made to allow
for the safe and unrestricted expulsion of the exhaust air. DO NOT
• block the exhaust manifold
• place objects in close proximity to the exhaust air
• place vacuum pumps in confined spaces
• touch the surface of the vacuum pump as it will become hot during operation
resulting in burns and scalding

Materials Suitable for Cutting
The machine is designed to cut, engrave and form a wide range of materials, as detailed below:
• Plastics - all plastics can be cut, including the 'hard' plastics such as polycarbonate.
• Woods - the majority of wood-based materials can be readily cut, including MDF,
plywood and other composite boards.
Note. When cutting some types of hard wood, e.g. mahogany, jarrah etc an appropriate
form of jigging will need to be considered.
• Metals - aluminium, brass and other soft metals can be readily cut. The hard metals
such as stainless steel can be cut, but due care must be taken regarding the depth of
cut, feed rate and cutter used. If in doubt, consult an appropriate person or the
manufacturers agent or machine supplier.
Other hard materials, such as carbides, should not be cut on the machine due to the risk
of damaging the machine or endangering the operator.
Note. When cutting metals a suitable lubricant should be used. Flammable fluids such
as Methylated spirit must not be used.
• Foams - all foam-based materials, such as sign foam, can be readily cut.
• Cardboard, rubber and insulation materials - most of these products can be cut using
an oscillating knife head
• Composites and Laminates - some composites and laminates, such as fibreglass, can
be cut. Please contact the manufacturers agent or machine supplier for more
information.
Dust Extraction
Dust may be produced during machining operations and this may introduce a risk of fire or
exposure of the operator to a hazardous substance. A suitable form of local exhaust ventilation
(LEV) must be fitted to the machine to remove machining dust. Outlets for extraction hoses are
fitted to the dust pickup head supplied with the machine. The hose must be firmly secured to the
fitting.
Note. Always ensure that the extraction system is clear of obstructions and is in correct working
order before using the machine. On dust extraction systems with manual cleaning devices follow
the manufacturers recommendation for regular cleaning. Filters should be cleaned daily.
Mist Dispensing Systems
Mist dispensing systems, such as Trico and UNIST cooling/lubrication systems, are designed
to assist in the cutting of ferrous and non-ferrous materials by delivering a fine mist of fluid under
controlled pressure. Only use recommended fluids in these devices. Flammable fluids such as
Methylated spirit must not be used and will cause damage to the devices. The use of non-
recommended fluids in mist sprayers will void manufacturers warranty.

Corrosion
Some of the components of the machine may be subject to corrosion in unfavourable conditions.
The machine should be used in a dry, moisture free atmosphere and should not be exposed to
water-based fluids or lubricants. The machine should not be exposed to acidic or alkaline
substances and it should be maintained in accordance with the servicing schedule.
General Safety Rules
It is essential that these instructions are made available to the machine operators. It is also
important to hand them on if the machine is sold or given to another user.
The machine should only be used by a suitably trained operator. Other personnel within the
organisation should be aware of the methods to stop the machine in an emergency.
The machine is intended for use solely as a 3-axis router and cutter of materials. It should never
be hammered on, nor used as a general workbench, or for any other purpose than that for which
it was designed. This is likely to damage the machine and may compromise operator safety. It
may also void the manufacturers warranty.
The machine must not be operated after the consumption of alcohol or the taking of any
medication or drugs which may cause drowsiness or loss of attention.
Machine must only be operated with all safety guarding in place. The machine cutting heads
including spindles and oscillating knife heads are supplied with safety guarding. Do not operate
the machine with safety guards removed. Do not activate clamping systems unless it is safe to
do so. Ensure all clamping devices are clear of obstruction and that machine operators or other
personnel cannot be injured prior to activating the device.
All emergency stop devices must be in full working order before operating machine.
We STRONGLY RECOMMEND that safety mats, laser safety curtains or other safety
barrier devices be fitted to machines with a process area exceeding 3600mm in length
or are fitted with aggregate head attachments or any other attachment that can pose a
safety risk. Safety interlock outputs are available on the controller for the connection of
these devices.
Machine must not be operated with danger or non-operation tags in place.
The machine must not be left unattended whilst in operation.
WARNING
Machine must only be operated by
persons trained and accredited by
Multicam Systems

Personal Protective Equipment
It is recommended that the operator, and other persons working in the vicinity of the machine,
use the following personal protective equipment in conjunction with the machine:
• Hearing protection
• Eye protection
• Gloves when handling materials to be machined
• Cut proof gloves when changing router bits, knife blades or other cutting tools.
Note: The supply and wearing of personal protective equipment is regulated by Workcover.
Training and Support Services Offered
In addition to the training provided during initial installation of your machine, Multicam offers a
range of extra training services as refresher courses or for the purpose of training additional or
new operators. These services may incur additional charges, of which you will be advised at the
time of application.
Onsite
We can provide onsite training to ensure a high level of machine operation competency
for your staff. Onsite training is beneficial in that it utilises your equipment and can be
tailored around your systems and procedures.
At Multicam Premises
Training at one of our offices can be provided for your staff. This is usually more general
training and is beneficial in that there are minimal disruptions. This type of training is well
suited to in-depth software training.
Remote Access
With Remote Access we log on to your computer via an internet client service. This can
enable us to assist you in diagnosing various operational or software issues. The service
can be affected by your internet connection or availability. Remote access is not suitable
for training new staff or staff with no prior experience, rather it is best suited to assist
previously trained staff or operators in areas that they may be unfamiliar with.
Remote access may also be employed by technicians to view your machine
configuration or settings.
To access additional training, please contact your nearest Multicam office.

Safe Operation of Machines
The machine must only be operated by persons trained and accredited by Multicam Systems.
The machine should be operated only in a well-lit environment in order that the operator can
monitor the working of the machine and carry out safe loading and unloading. If the workplace
is poorly lit, then additional lighting will need to be provided.
The machine's safety devices should be checked regularly for correct operation, e g the
emergency stop mechanism and guarding.
When the machine is running, keep clear of any rotating or moving parts, e.g. the cutting bit,
spindle, moving gantry and head parts.
Do not stand or lean on the machine whilst it is in operation. No persons other than the operator,
or other authorised persons, should enter the working area whilst the machine is in operation.
Parts of the machine, particularly the cutting bit, may become hot during use. Take care when
handling these parts and wear protective gloves if necessary.
Prior to operating the machine the following safety checks must be performed:
• Ensure that there are no tools or materials left on or near the rack and bearing rails of
the gantry and the axis of movement.
• Ensure all guarding is in place including dust extraction devices. The machine cutting
heads including spindles and oscillating knife heads are supplied with safety guarding.
Do not operate the machine with safety guards removed.
• Ensure that all clamping systems are free of obstructions and that no other personnel
are likely to be injured or engaged prior to activating the clamps.
• Ensure that all tools have been removed from the cutting area.
• Ensure that the guards are in place and correctly positioned.
• Ensure that the material being cut and the sacrificial board is no wider or thicker at any
point than the width and height under the gantry and does not impede the movement of
the gantry.
• Ensure that only recommended cutting fluids are used in mist dispensing systems.
• Ensure that all cutting tools to be used are sharp and in correct working order.
• Ensure that the filter for the vacuum pump is clean and that the correct vacuum valves
are On/Off and are clear of any obstructions.
• Ensure that there is at least 500mm of clear open space around the machine.
• Ensure that all electrical and air supply components are in correct working order and
have not been damaged in any way.
• Ensure that the vacuum pump inlet/outlet ports and pressure release valve are not
covered.
• Ensure that the area around the machine is clean and free from obstructions which could
lead to slips, trips or falls.
• Ensure that tools are correctly fitted in to collets and that collets are free from wear or
damage.
• Ensure that ISO tool holders are in good condition and are free from wear or damage.
• If manually changing tools in a quick tool change motor ensure that the tool holder is
correctly engaged in the motor. Do this by firmly grasping the nut on the tool holder and
pulling in a downward and sideways movement and checking for looseness. If you are
able to "wobble" the tool holder it is not correctly engaged.
It is recommended that checklists are used and logged at the end of each shift.

Safety During Maintenance
Changes or additions to the main electrical system in connection with the installation and
operation of the machine should always be carried out by a suitably competent and licenced
electrical engineer.
Repairs carried out by untrained or unauthorised personnel may result in personal injury or
serious malfunction and damage to the machine.
Do not alter or modify the specification of the machine as this may introduce an uncontrolled
hazard or risk.
Servicing and maintenance of the machine should be carried out on a regular, planned basis
and by a trained and authorised engineer.
Before working on any component or part of the machine always isolate the machine from the
mains electrical and air supplies. These should be locked off.
Safety During Cleaning
To maintain optimum performance and obtain the longest service life from the machine, it must
be cleaned regularly, either with a vacuum cleaner, compressed air or a suitable cleaning
solution. When cleaning, the machine must not be in operation. Extra care must be taken if
using compressed air to clean the machine that particles are not blown off the machine into the
eyes.
Do not use pressurised jet washers or free flowing liquids to clean the machine. These will
damage the machine.

Warning Labels
The following chart details the warning signs and labels and their locations on the machine.
They are designed to assist and remind the operator to exercise caution when approaching the
machine and the working area.
Operators should read carefully and take due note of the warnings and instructions for safe
operation before operating the machine.
In addition to the warning labels on the machine the workplace should also be adequately
signed for the wearing of personal protective equipment, e g eye and hearing protection, and
the zones where these precautions are necessary clearly marked.
HAZARD NOTICE TABLE
Hazard Requirement Location
Hearing Protection Mandatory On the Machine Head
Eye Protection Mandatory On the Machine Head
Electrical Power Warning On the Inverter Box
Electrical Power Warning On the Controller Box
Electrical Power Warning On the Power Box
Cutting Hazard Warning On the Machine Spindle
On Knife head attachments
Emergency Stops Mandatory On both ends of the Gantry
Air Pressure Warning On the Machine Frame
Striking Warning On the X axis Bearing
Cover
Striking Warning On the Tool Changer Cover
Striking Warning On the Machine Head
Pinch Point Mandatory Near clamp activation
switch
Cutting Hazard Mandatory On the Spindle pickup
housing
On Knife head attachments
Position or appearance of labels may very in accordance with devices that form
part of the work cell. Always observe all safety labels and advisory notices.
Note. The warning labels must not be removed from the machine.

Safety Rules
MANUALS. Always read the appropriate manual or instructions before attempting to operate
or maintain equipment. Make sure that you understand all instructions.
CORRECT SUPERVISION. When in doubt as to the correct way to operate the equipment
always consult your supervisor.
OPERATION OF EQUIPMENT. Do not operate equipment unless maintenance has been
performed on a regular basis, and the equipment is known to work properly. Do not operate the
machine with safety guards removed. The machine must not be left unattended whilst in
operation.
EMERGENCY SWITCHES. Ensure that you know where all emergency switches and stop
buttons are, and you know how to isolate the machine from the main power supply.
WARNING NOTICES. Do not remove any of the warning notices or mandatory signs from the
machine. Ensure that you comply with all such information.
SAFETY DEVICES AND GUARDS. Inspect all safety devices and guards to be certain that they
are in good condition and functioning properly before any operation. The machine is supplied
with guarding required for safe operation. Do not use the machine unless safety guards are in
place.
HAZARDOUS CONDITIONS. Do not operate the machine if unusual or excessive heat, noise,
smoke or vibration occurs. Switch off the machine and report any unusual occurrence.
EARTHING. Ensure that the equipment is properly earthed. The equipment contains digital
signal systems, which are effected by electrical spikes and noise.
ELECTRICAL ISOLATION. Before any repair or maintenance work is undertaken on the
machine ensure that the main electrical power is fully isolated.
MAINTENANCE WORK. Do not reach into any control or power box unless the electrical power
is turned off, do not touch any electrical equipment if hands are wet or when standing on a wet
surface.
AUTHORISED PERSONNEL. Do not allow unauthorized personnel to have access to electrical
enclosures containing electrical equipment. Do not allow untrained personnel to operate or
repair the equipment.
REPLACEMENT EQUIPMENT. Always replace blown fuses with fuses of the same rating, size
and type as the original.
WARNING
Machine must only be operated by persons trained
and accredited by Multicam Systems

PERSONAL PROTECTIVE EQUIPMENT. Wear the correct safety glasses, ear protection and
foot protection at all times.
LOOSE EQUIPMENT. Do not operate any machine while wearing rings, watches, jewellery,
loose clothing, neckties or untied long hair.
SAFE WORKING AREA. Keep the area around the equipment well lit, dry and free from
external obstructions and waste material.
FLAMMABLE EQUIPMENT. Keep chemical and flammable material or products away from
electrical or operating equipment.
FIRE EXTINGUISHER. Always have the correct type of fire extinguisher ready when machining
combustible material and keep chips clear of the work area.
MACHINE OPERATION. Do not operate any equipment while anyone is close to any potentially
hazardous area.
PINCH POINTS. Always beware of pinch points created by moving components of equipment
including automatic, semi-automatic or manual clamping devices.
LOOSE TOOLS AND EQUIPMENT. Remove any loose parts, work pieces, or tools left in the
operating area of the equipment, which may come into contact with moving machinery.
WASTE MATERIAL. Do not remove splinters, chips, swarf or waste material with bare hands.
Beware of sharp and burred edges on newly machined work pieces.
ADJUSTMENT OF MACHINERY. Do not adjust tooling or mist dispensers or extractor hoses
while the machine is running.
CUT MATERIAL. Do not attempt to remove any cut material while the machine is running.
BRAKING OF MACHINERY. Do not attempt to brake or slow down the machine with your
hands or any foreign device.
CUTTING TOOLS. Be cautious when working around cutting tools, their cutting edges are very
sharp and can cause injury.
MOUNTING TOOL SURFACES. Make certain that all tool-mounting surfaces are clean before
mounting tools.
LOADING AND UNLOADING THE MACHINE. Ensure correct manual handling procedures are
observed when loading and material and product from the machine. DO NOT attempt to remove
items from the machine bed whilst the machine is in operation.
ALWAYS THINK SAFETY FIRST

Vacuum Pump Operating Information
To protect the vacuum pump from premature failure it is important that the following
procedures be adhered to;
Maximum Pressure
The maximum allowable pressure is not exceed -40kPa. Exceeding this value will cause the
pump to overheat causing severe damage and voiding warranty.
Operating Temperature
The vacuum pump surface will become extremely hot during operation. Care must me
exercised when coming in to contact with the surface of the pump or any other items likely to
become affected by heat.
Vacuum pump performance is affected by the ambient and inlet temperatures. Vacuum
pumps must not be operated where the inlet temperature exceeds 50oC. As the inlet
temperature approaches 40oC the vacuum pump must operate at a reduced duty cycle
allowing time for adequate cooling of the pump between cycles. Duty cycle is determined by
ambient temperature. The higher the ambient temperature the shorter the duty cycle.
Vacuum pumps expel hot air at high velocity. Adequate provision must be made to allow for
the safe and unrestricted expulsion of the exhaust air.
DO
• ensure that there is adequate space around the vacuum pumps to allow a free flow of
air on all sides. We recommend a least 1m of free, unobstructed space on all sides.
• keep vacuum pumps clear of debris.
• check correct function of relief valve regularly.
• consult with specialists if you intend to duct exhaust from the pump. Incorrect ducting
will affect vacuum pump performance and can lead to failure of the pump and
overheating leading to injury or fire.
DO NOT
• exceed the maximum operating pressure.
• exceed the maximum inlet operating temperature.
• block the exhaust manifold.
• place objects in close proximity to the exhaust air.
• place vacuum pumps in confined spaces.
• enclose the vacuum pumps in enclosed spaces.
• place vacuum pumps under machines unless absolutely necessary. This will result in
limited air flow around the pump causing premature failure and a drop in performance
and cause surrounding machinery to become affected by heat.
• touch the surface of the vacuum pump as it will become hot during operation
resulting in burns.
• move the vacuum pump from its originally installed location.
Failure to follow these instructions will void your warranty

Job Design Considerations
Before designing a job for cutting on the machine there are a number of factors that must be
taken in to account. A designer must always consider how the component is to be produced
using the machine, tooling and materials available. Sometimes the design requirements will
place demands on the tooling that could lead to undesirable practices such as the use of
small diameter or extra long tooling. These must be avoided as far as practicable and
attempts should be made to alter the design to reduce these practices.
It is essential that when designing a job for manufacture the programmer is conversant with
the machine capabilities, characteristics of the materials being cut and the available tooling.
In cases where there is no control over the design of the component to be cut then the
overriding consideration must then be to the safe and efficient cutting of the component. The
order of priority of these considerations will be dependent upon the nature of the job.
Physicality of the component
The physical nature of the component (i.e shape and material to be used) to be machined
will determine factors such as;
• work holding
• cutter selection (diameter, length, flute geometry)
• cutting speeds and feed rates
• number of cutting passes
• edge finish
Work Holding
The material to be cut must be safely secured to the machine bed. The use of jigs or manual
clamping methods may be required depending on the size and shape of the item to be
machined and the material it is to be cut from.
If using vacuum tables the operator must ensure that minimal “leakage” is present to
maximise the effectiveness of the system. If too much leakage is present then materials and
components may move during the cutting process. The number and size of through cuts, the
size of the component being cut, the condition of the sacrificial board, the speed of cut and
diameter of the cutter being used will all influence the performance of the vacuum system.
If using manual clamping methods or jigging, consideration must be given to the placement
of clamps, height of clamps, number of clamps and proximity of clamps to machining paths.
The programmer and machine operator must ensure that travel clearance heights and clamp
location will not cause the cutter or any other part of the machine to strike any of these
items.
If automatic, semi-automatic or manually activated clamping devices are fitted to the
machine, care must be exercised to ensure that there is no risk of injury or engagement with
the devices by operators or other persons.

Cutter Selection
Choose a cutter that is appropriate for the material to be cut and the edge finish required.
Use of a tooling catalogue will assist in this process. The number of flutes, the flute profile,
the direction of the flute will all affect speed of cut and edge finish. There will always be a
trade off in speed of cut, edge quality and cutter life that should be considered in your
production process.
Always use a cutter with the shortest possible length to safely machine the part. This will
assist in reducing breakage, vibration and wear. It will also aid in increasing cutter life and
improving edge finish. As a general rule the cutter edge length (CEL) should not be greater
than three times diameter of the cutter, however tooling manufacturers do produce cutters
that exceed this for specialist operations.
For a detailed explanation of cutters and their use refer to your cutter supplier catalogue.
Cutter manufacturers offer technical specifications and recommendations for their products.
Cutting Speeds and Feed Rates
These are determined by the following factors
• Material to be cut
• Edge finish required
• Cutter selected
• Machine properties
• Production requirements
• Cutter life span
• Work holding method
The order of priority of these factors is the responsibility of the Production Manager and is
usually made on a job by job basis. Sometimes speed of production will outweigh the
importance of edge finish or vice versa. The programmer must be made aware of these
requirements prior to programming the job for the machine.
In determining cutting speeds and feed rates the machine operator and programmer need to
know the cutting properties of the material being cut. This information is obtainable from the
material supplier who can usually provide chip thickness information and optimal cutting
rates.
Tooling manufacturers can provide specific cutting data for their tooling.
Obviously it becomes impractical to look up this information every time you commence a job.
For this purpose we have provided general information and a cutting table in this manual.
Most tool catalogues will also have this type of information for quick reference.

Number of Cutting Passes
The number of cutting passes required is determined by the following factors;
• Depth of cut
• Diameter of cutter in use
• Material being cut
• Edge finish
The order of priority of these factors is the responsibility of the Operator and Production
Manager and is usually made on a job by job basis. Sometimes two passes at a high feed
rate will actually produce a shorter cycle time than a single deeper pass that requires a
reduction in feed rate. The programmer must be made aware of these requirements prior to
programming the job for the machine.
Edge Finish
The quality of the edge finish is determined by the following factors;
• Requirement of the finished product
• Depth of cut
• Diameter of cutter in use
• Material being cut
• Wear of the cutter
The order of priority of these factors is the responsibility of the Operator and Production
Manager and is usually made on a job by job basis. Sometimes the edge finish is paramount
in the final product so all care is taken to ensure this result. On other occasions edged finish
can be sacrificed for the sake of higher productivity. The programmer must be made aware
of these requirements prior to programming the job for the machine.
A reduction in edge finish can generally be attributed wear on the cutting edge of the cutter.
When this becomes apparent the cutter must be replaced to prevent sudden and
unexpected breakage.

Cutter and Collet Usage
Handling Cutters
• Cutters are extremely sharp. Extreme care must be observed when handling cutters
to prevent injury. The use of gloves is recommended.
• Always store cutters in their cases when not in use
• Always wear protective eye wear when handling cutters.
• Do not drop cutters as this can cause micro fractures leading to unexpected
breakage once in use.
Inspecting Cutters
• Before using a cutter inspect it for any sign of damage or wear.
• Cutters that show chipping on the edge must not be used.
• Cutters with scored, bruised or marked shanks must not be used.
Determining Cutter Life
The life expectancy of any cutter is directly affected by the following factors;
RPM
Cutters running at too high an RPM will wear prematurely due to excessive heat and friction.
Typically this can by observed by very fine chips, squealing whilst cutting, burring along the
top of the cutting edge, “loading” of material in the cutter flutes (especially in non ferrous
materials) or burning on the cutting edge, especially in corners.
Running a cutter at too low an RPM will result in breakage.
Feed Rate
Cutters running at too low an feed rate will wear prematurely due to excessive heat and
friction. Typically this can by observed by very fine chips, squealing whilst cutting, burring
along the top of the cutting edge, “loading” of material in the cutter flutes (especially in non
ferrous materials) or burning on the cutting edge, especially in corners.
Running a cutter at too high a feed rate will result in poor edge finish and cutter breakage
Vibration
Excessive vibration during the cutting process will affect cutter life and edge finish. Steps
should be taken to ensure that the workpiece is as rigid as possible. This will include keeping
cutter length to a minimum, using as large a cutter diameter as possible, ensuring adequate
work holding. In some cases, especially when machining extrusions, vibration will be difficult
to control.
Collets
Worn or dirty collets will mean that the cutter is not being held securely thus resulting in
vibration and breakage. Ensure collets are clean and replaced at the end of their duty cycle.
Please refer to page 18 for further information on collet maintenance.

Suggested Feed Rates
PRODUCT FEEDRATE PLUNGE RATE DIRECTION TOOL DIA
3mm Acrylic 3000mm/min 1200mm/min Climb 3.175mm
4.5mm Acrylic 2500mm/min 1200mm/min Climb 3.175mm
6mm Acrylic 2500mm/min 1200mm/min Climb 4.76mm
10mm Acrylic 2000mm/min 1000mm/min Climb 6.35mm
20mm Acrylic 1500mm/min 800mm/min Climb 6.35/8mm
3mm Aluminium 2500mm/min 400mm/min Conventional 3.175mm
6mm Aluminium 1800mm/min 300mm/min Conventional 4.76mm
10mm Aluminium 1500mm/min 200mm/min Conventional 6.35mm
12mm Aluminium 1500mm/min 800mm/min 4 passes Conventional 6.35mm
10mm MDF 12000mm/min 1200mm/min Conventional 4.76mm
16mm MDF 12000mm/min Ramp Plunge Conventional 12.70mm
16mm Whiteboard 12000mm/min Ramp Plunge Conventional 12.70mm
20mm MDF 8000mm/min 800mm/min Conventional 8/12mm
10mm Plywood 8000mm/min 1200mm/min Conventional 4.76mm
16mm Plywood 7000mm/min 1200mm/min Conventional 6.35mm
25mm Plywood 6000mm/min 800mm/min Conventional 8/12mm
12mm Hardwood 6000mm/min 1000mm/min Conventional 6.35mm
19mm Hardwood 4000mm/min 800mm/min Conventional 6/8mm
35mm Hardwood 2000mm/min 700mm/min Conventional 12/16mm
Note: Hardwood Feed rates are based on medium hardwoods.
The above settings are a guide only. A number of factors including spindle type, tool selection,
sharpness, and material holding must be taken into account. There are a variety of tools that appear to
have the same specifications, however differences such as spiral direction and length of cut to give
different results in different materials. If you require tool assistance or recommendation please contact
us.
TOOL GEOMETRY
STRAIGHT FLUTE: The straight flute design does not allow for lifting of material out of the cut.
SPIRAL FLUTE: The spiral flute will allow swarf to be lifted out or pushed into the cut
depending on the flute geometry. Spiral flutes can be used with most
materials.
FLUTE GEOMETRY
SINGLE FLUTE: Single flute cutters only have one cutting edge, use for faster feed rates in
softer material.
DOUBLE FLUTE: Double flute cutters have two cutting edges, these tools provide a better finish
in harder material at lower feed rates.
UPCUT SPIRAL: These cutters provide for upward chip evacuation. They should be used for
grooving, slotting or whenever the best finish is needed on the bottom side of
a part.
DOWNCUT SPIRAL: Used for downward chip flow, better hold down in fixture and best finish on the
top side of the part.
COMPRESSION Used for double laminated material and best finish on top and bottom
CUTTERS: side of the part.
O FLUTE: Identified by the half-moon shape of the cutter. The O Flute is classified as a
single flute cutter. This bit is best suited for routing timbers and plastics. This
design provides for optimum chip removal at very high feed rates.

How to Avoid Tool Breakage
Most CNC tool breakages are caused by incorrect or faulty colleting
A router tool spinning at 18,000rpm is in trouble if it's as little as 5 microns off centre. This is
about how thick a deposit of resin or dust is when it's squashed inside the collet.
Collets are manufactured to exacting tolerances and when they are 5 microns out of round
both the collet and the tool are strained because the distorted collet cannot grip the tool
shank perfectly.
This results in
• Poor component edge finish
• Less than optimum tool life
• Metal fatigue and eventual breakage of the tool
• Increased noise.
The extra noise is a clue as to what is happening to the machine. Tool run out causes high
frequency vibrations in the high speed motor bearings. This drastically reduces their service
life.
Colleting and Collet life Span
Collets have a life span of 3 months if used 8 hours a day. Replacing the collets will ensure
that your operation runs consistently and prevents tool breakage. When inserting a tool into
the collet, make sure the flute fade out does not enter the collet. If the collet is gripping on
the fadeout, it will cause runout and potentially tool breakage. To ensure proper clamping the
tool shank should fill, at a minimum 80% of the depth of the collet.
Collet Maintenance
Cleaning is an essential part of collet maintenance. As material is cut, extremely fine dirt and
resin migrates up the tool shaft into the collet, causing the collet, collet nut, toolholder and
spindle interface to become dirty. This causes your tool to cut in an elliptical fashion which
will decrease tool life and cause inconsistency in your operation.
Keeping collets and tool holders clean is as essential as it is easy.
• Do not allow dirt to build up in the collet, cover nut or tool holder.
• Always clean mating surfaces prior to fitting.
• Do not used damaged collets, tools or tool holders.
• Do not leave tools or tool holders in spindles for extended periods of time.
• Replace collets and tool holders if they show any signs of damage.