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need suggetion for cutting exact 25mm x 25mm x 25mm walnut wood cubes

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Forum topic by Muhammad Umer posted 03-04-2010 02:31 PM 1171 views 0 times favorited 22 replies Add to Favorites Watch
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Muhammad Umer

31 posts in 1676 days


03-04-2010 02:31 PM

dear friends

i need to make 40000 pcs of walnut wooden cubes and size is 25mmx25mmx25mm any help to make them fast and accurate ????

-- Muhammad Umer "sumrgroup@gmail.com"


22 replies so far

View TheDane's profile

TheDane

3810 posts in 2330 days


#1 posted 03-04-2010 03:19 PM

Joint your over-sized rought stock so you have two faces that are 90-degrees. Then on the tablesaw, rip the stock to 25mm width with one of the jointed faces down on the table and the other jointed side on your fence. Rotate the stock 90 degrees and rip again. This should yield a square piece of stock 25mm x 25mm x whatever the length is.

If you don’t have a sled for your table saw, you can make a temporary one with two pieces of scrap screwed to your miter gauge. Set the sled up so you have more than 25mm on the off-cut side of the blade. Measure and mark the fence so the off-cut is 25mm long, and test.

I have done this many times using a piece of hardwood for the back of the sled and hardboard for the table. The hardwood backs up the cut, reducing tearout. It has always worked like a charm for me.

-- Gerry -- "I don't plan to ever really grow up ... I'm just going to learn how to act in public!"

View Sawkerf's profile

Sawkerf

1730 posts in 1736 days


#2 posted 03-04-2010 11:04 PM

Do you really mean 40,000 pieces??

-- Adversity doesn't build character...................it reveals it.

View Muhammad Umer's profile

Muhammad Umer

31 posts in 1676 days


#3 posted 03-04-2010 11:23 PM

yes i have to cut them and quantity is 40000 pcs

-- Muhammad Umer "sumrgroup@gmail.com"

View MrsN's profile

MrsN

940 posts in 2193 days


#4 posted 03-04-2010 11:28 PM

wow, that is a lot of pieces. Can I ask what they are for?

-- ----- www.KNWoodworking.com ----- --

View Muhammad Umer's profile

Muhammad Umer

31 posts in 1676 days


#5 posted 03-04-2010 11:29 PM

dear Dane

thank you very much for the advice i am sure this way will be quiet helpful and productive. i am just going to try out some test production to get idea of accuracy.

thanks

-- Muhammad Umer "sumrgroup@gmail.com"

View Sawkerf's profile

Sawkerf

1730 posts in 1736 days


#6 posted 03-04-2010 11:59 PM

Wow, that’s a lot of cutting. Translating it to english units, you need to mill your stock into ~3300 linear feet of ~1” x 1” pieces, then cross cut them to ~1” lengths which means ~3300 feet of crosscutting.

What kind of shop and tools do you have? I have a decent shop, but would probably pass this job to a production shop with computerized equipment. No way could I guarantee speed and accuracy.

-- Adversity doesn't build character...................it reveals it.

View GaryK's profile

GaryK

10262 posts in 2655 days


#7 posted 03-05-2010 12:09 AM

With that much cutting it would be well worth it to spend the time to make a fixture that will position the piece as well as remove it after cutting.

-- Gary - Never pass up the opportunity to make a mistake look like you planned it that way - Tyler, TX

View Muhammad Umer's profile

Muhammad Umer

31 posts in 1676 days


#8 posted 03-05-2010 12:09 AM

well i don’t have a shop but two factories and large list of machinery but not computerized i am based in Pakistan and done very large projects just like making doors, furniture, windows etc… but in my 11 years of experience this first job which makes me confuse because my customer needs accuracy of size nothing else.

i do have 1 cnc carving machine, 3 circulatory saws, 5 gauge planers , 3 band saw 39” , one saw mill for lumber cutting , mittre saws,three table cutters 4ft x 6ft , 2 spindles and many other hand tools

-- Muhammad Umer "sumrgroup@gmail.com"

View GaryK's profile

GaryK

10262 posts in 2655 days


#9 posted 03-05-2010 12:13 AM

Just how accurate do the need to be?

-- Gary - Never pass up the opportunity to make a mistake look like you planned it that way - Tyler, TX

View Muhammad Umer's profile

Muhammad Umer

31 posts in 1676 days


#10 posted 03-05-2010 12:14 AM

well accuracy required 25.4mm x 25.4mm x 25.4mm

-- Muhammad Umer "sumrgroup@gmail.com"

View teenagewoodworker's profile

teenagewoodworker

2727 posts in 2435 days


#11 posted 03-05-2010 12:23 AM

i would say if you don’t have a drum sander… invest in one. you can sneak up on the pieces and get really good accuracy. with a table saw the pieces are going to come out warped and there is really no way you can get this precision on a table saw. its impossible. rough cut the pieces and then sand them down. then for crosscutting you’re gonna have to go to the table saw but thats not so bad. just make a jig to hold everything and make sure the square is held securely so it doesn’t hit the back teeth of the table saw or fall into the blade or something.

View GaryK's profile

GaryK

10262 posts in 2655 days


#12 posted 03-05-2010 12:24 AM

So they have to be between 25.00mm and 25.4mm?

That’s not too bad. Like I said above make a fixture that will position the piece as well as remove it after cutting.

It goes without saying that you need to start with some square 25mm x 25mm stock. A jointer and planer should take of that.

-- Gary - Never pass up the opportunity to make a mistake look like you planned it that way - Tyler, TX

View jm82435's profile

jm82435

1280 posts in 2409 days


#13 posted 03-05-2010 01:19 AM

Wow! That is a lot of cutting. I don’t see a problem cutting a 25mm cube accurately but rather how do you efficiently cut 40,000 of them. I envision long strips of 25 X 25 stock clamped together probably as high as your saw blade will reach and as wide as your table or jig will allow batch cut on a sliding jig. A small kerf would also be nice given the amount of waste involved. If they are all stacked and clamped together in and array (on a table saw maybe 5 strips high x 20 strips wide you are still talking about 400 cycles through the saw and depending on the lengths of the strips at least a half dozen bundles 5×20 strips) As Gary said you need something that will position and clear the cubes as you cut them. I envision a sled with a stop block and a tall fence in the back that would help clear the cut cubes on the waste side as well. Good luck & tell us what you come up with.

-- A thing of beauty is a joy forever...

View TheDane's profile

TheDane

3810 posts in 2330 days


#14 posted 03-05-2010 01:23 AM

Egad … I missed the reference to 40-thousand!

-- Gerry -- "I don't plan to ever really grow up ... I'm just going to learn how to act in public!"

View SNSpencer's profile

SNSpencer

133 posts in 1780 days


#15 posted 03-05-2010 02:56 AM

As for the extraction of the cut cubes I could see setting up a 4 inch “suction” tube attached to the saw table top (maybe magnetic attachements). Just use the power of a dust collection system to safely and quickly suck the cut cubes off the table and away from the blade as they are cut. I understand that the end of the tube would need to be pretty close to the the material being cut, but set up just right it could work.

Also, if you use a sled to make the cuts you engineer it to raise the material up an eighth to quarter inch or so and have a 45 deg “ramp” on the cut cube side of the blade. This would help move the cubes away from the blade as they “fall” after being cut.

-- Jef Spencer - Refined Pallet - http://www.etsy.com/shop/RefinedPallet

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