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.
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.
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
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.
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.
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.
Ok, I'm going into engineer mode here. (30 years as a Mechanical PE taught me a couple of things. - lol)
What's the acceptable tolerance for these cubes. 25.4 mm +/- ?? mm?
What kind of wood are you using? What is its coeffecient of thermal expansion?
Do you get to pick the temperature and humidity conditions for making your measurements to prove that you met the specs?
Right off, I would say that only your CNC machine would have the accuracy and precision necessary to do this job. Nothing else you mentioned (particularly the bandsaw and hand tools) will come close.
I would have the 25.4×25.4 squares of wood made on a four sided moulder and then set up a very accurate crosscut jig to make them into cubes. THis will save you a whole lot of time and headache. A small pneumatic plunge type clamp can be used to secure the pieces that while cross cutting.
I'm with the other guys. Mill down some pieces that are 25×25mm x however long.
Make a table saw sled and maybe even automate it somehow. You could use air to blow the piece out of the way after cutting. If it was me I'd invent a way to automate this step as this will be the most time consuming part. The whole thing will take a really long time even if automated. 40,000 is a lot. If it was me I wouldn't take the job unless I could automate the cutting somehow. Perhaps a CNC router table is the way to go? thats a lot of pieces for any shop that is not already set up to do so. I'd love to see what you come up with.
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