Here is a breakdown of what each of these factors entails and a closer look at why feed rate optimization is so important to the success of your operation.

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Wiping the sawdust from his face, Leonard Robertson looks out to watch an endless sea of barley toss about in the wind. “I should be fishing today. Bet they’re biting good back on the ’Hawk [the Shiktehawk stream]. Yeah, that sure would be nice. Maybe tomorrow.” He turns back to the job at hand of running a small sawmill in northern New Brunswick. But this is not your typical industrial sawmill of the 21st century. This mill and the man who runs it are a living link to Atlantic Canada’s long history with lumber.

Cutting speedandfeed ratefor milling

“A person gets shot at sometimes at this job. You get old hunks of fence staples or barb wire. Saw hits that and zing! Anywhere an old clothesline hung is the worst. Big old pulley and good-bye sharp teeth. No point in ducking, it’s all over when you hear it flying. I get a few scares every year. Spiders too. They hide in cedar mostly great big hairy monsters like you wouldn’t believe. They’ll crawl out of a crack as the saw comes along. Big as your hand.”

With a wry smile Leonard says a long day’s yield of lumber would be a whisker of a bigger operation. “I can get a 20-footer on the carriage, but much bigger it’s an awful struggle. Seventeen inches is about all I can saw through, so sometimes you have to turn it over and run it through again. Cut truckloads of lumber for buildings, barns, even potato houses. Bridge frames, walking trails, whatever. Cut a million stickers. You have to have separation between the boards so you run strips of wood so things dry right.”

Spindle rpm or spindle speed is the rate at which the spindle revolves while cutting. This should also be set to a value appropriate for the tool being used and the material being cut. It is sometimes possible to cut at a faster feed rate by increasing the spindle rpm. If you cut at too low of a feed rate or with too high of a spindle rpm, there is a risk of overheating the router bit and burning or melting the workpiece.

We walk outside and Leonard grabs a few two-by-fours. He lugs the lumber to a stack and gets it lined up correctly. “That look right Anthony?” Nodding in agreement, Anthony runs a thin piece of wood at three places on the pile. Both men survey the growing stacks of lumber, blinding white in the sun.

Cutting speed feed ratecnc

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Feed rate optimization features allow you to set the distance before the corner to start feed rate reduction and the distance after the corner to increase back to its initial speed. You can also control the percentage by which speed is reduced coming in and out of corners. For example, you could have the feed rate slow down by 50% a half inch from the corner and then remain at 50% until half an inch out of the corner.

Cutting speed feed ratecalculator

Feed rate refers to the distance the cutting tool travels during one spindle revolution, as well as to the velocity at which the cutter is advanced against the workpiece. It can generally be thought of as how fast the machine moves the router bit through the material when cutting. The feed rate is typically measured in units per minute (i.e., inches per minute).

Feed rateunit

Setting the peavey aside Leonard uses a tape measure to check the smaller end of the log before clamping it in place on the carriage “See here? I can get five two-by-fours over 16 feet long. Full sized too, not the skinny ones you buy. Maybe get a couple boards too, we’ll see.”

Slew rate, also known as rapid speed, refers to the speed at which the machine moves when above the material traveling between cuts. In most scenarios, the slew rate is set as high as possible to help reduce cycle times and improve efficiency.

This is important because too low of a feed rate can produce chatter, vibration, and work hardening, in addition to resulting in poor surface finishes and premature cutter failure. On the flip side, too high of a feed rate can cause excessive cutter loads, chatter, vibration, and unsafe conditions, and can also lead to the failure of the tool, spindle, fixture, and machine.

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Cutting speed feed rateformula

Feed rate is not to be confused with cutting speed, which refers to the relative velocity between the surface of the workpiece and the cutting tool and deals more with factors like tool life and power consumption.

Cutting speedformula

Leonard has sawdust in his blood and spent years cutting with a chainsaw all over New Brunswick. “We cut different back then, left the small stuff to grow bigger. Cold and wet I been in those old swamps in winter, snow down your neck. Sitting up on a freezing skidder seat, haulin’ all day. Here I’m out of the wind. Do a dozen jobs, sharpen the teeth, haul sawdust, run the loader. No, it’s a better job for sure. I must like it ‘cause I been at it for over 25 years now.” With obvious pride in his voice he says, “I can run all the edgings back through and get more boards. A big operation just tosses that rough stuff aside, too much bother. I like to get every piece I can. If someone was doing it for me I’d want them to do it the same.”

Think of the cutter like a car. If you were driving 100 mph approaching a 90-degree turn, it would be smart to slow down ahead of time. This is where feed rate optimization comes in.

Feed rateformula

The sawmill sits up high looking down on a broad valley of the Monquart Stream; Leonard often sees wildlife in the country below. “Seen some big bear, deer and moose all the time. Fall comes and there’s a thousand Canadas [geese] out flying by. I’m on my own here and that’s fine.” Looking troubled for a moment, Leonard says, “No one’s interested in this work now. Too hard for ‘em and I haven’t had anyone but you show up to ask questions. No one wants to learn this trade. Who’s going to run these small sawmills in 10 years? No one’s doing nothing for themselves today. Too busy, I guess.”

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The suggested feed rate for a given project will vary depending on the material you are cutting, the material of the cutter itself, and several other factors.

Cutting speedunit

This type of rotary sawmill once numbered in the hundreds across Atlantic Canada filling lumber orders big or small. The history of sawmills in Atlantic Canada can be traced back to the late 17th century when a mill was located on the Nashwaak River, near Fredericton, NB. By the middle of the 19th century sawmills were spinning in all four provinces with an 1845 census showing more than 645 in New Brunswick alone. Nova Scotia had numerous water-powered mills and many used a vertical blade drawn up and down. PEI sawmills date back to the 1790s. Newfoundland had fewer sawmills but lumber production rose steadily all through the 1800s until the advent of the pulp and paper industry. Many were small operations but all provided building materials for export and the bustling pioneer farms that sprang up. Barns, houses, and fishing docks all had their own requirements and the local sawmill provided it. Communities sprang up in the sawmill’s shadow with stores, schools and pride. Today a sawdust burner stack is an object of scorn, but once it represented industry and most importantly steady employment. Wood was the lifeblood inland and the equal of the fish stock riches of the cold Atlantic.

In the CNC world, the most notable group of these parameters are feeds and speeds a term generally used to refer to feed rate, cutting speed, slew rate, plunge rate, and spindle rpm.

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Customers often come to Leonard with specific requests. “Fellow comes here, he wants so many two-by-eight board and so many two-by-four, or boards to do walls plus the roofing. Tell me what you want, get me the logs and I can make ‘er!”

Once the logs are clamped in place Leonard operates a hydraulic system which sends the carriage down the line to the spinning saw. Forty teeth send a spray of wood chips upward and the resulting cut lumber falls away to be removed. Leonard’s son Anthony is working today stacking lumber. “Anthony’s my main man,” Leonard says smiling. Father and son work with little conversation, hands practiced from countless hours. All the cutting is done by eye and skill alone. “I’ve learned to keep all the sizes straight and the board feet calculated per thousand feet.”

Many parameters must be considered when setting up a job on your CNC router or plasma, especially if you hope to achieve optimal precision, quality, and efficiency.

Most CAD/CAM packages today include a feed rate optimization feature to address this, in addition to helping reduce cycle times, increasing tool life, and ensuring all cutting operations maintain a constant chip thickness.

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The sound of a combustion engine in distress is like a siren call to Leonard, who has never tired of mechanical work. “Got into fixing engines pretty young. Just seemed to interest me, seeing how it worked, how the power was made and keeping things running smart. Big job looking over an engine. Motors all have their own reasons to be not working, but it’s nice when you get it humming right. Open ‘er up and hear things working right, that’s what I like. Why junk something you can fix? Get it repaired run it another 10,000 miles why wouldn’t you?” It’s a green notion in this age of throwaway machinery and an idea rural folks have never abandoned.

Leonard returns to his station at the saw controls. As a huge spruce hits the saw a smile crosses his face, and a thousand old sawyers smile with him as the chips continue to fly.

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Plunge rate is the speed at which the router bit is driven down (or plunged) into the material when starting a cut. The ideal plunge rate will vary depending on the bit used and the material being cut, but it is always important not to plunge too quickly as this can damage the tip of the cutter.

Feed rate optimization is important to maximizing the efficiency and quality of a cut. It can also help preserve the long-term condition and performance of your CNC machine.

The phrase self-taught can sometimes be a bit of a cliché but for Leonard it’s as true as the straight lumber he mills. “I never did any sawmill work until the day I stepped in here. Walked up, looked it over and went to work. Boys, it was wild stuff for a few days. Ruined a couple logs,” Leonard admits, “But I kept at it. Got better over time and learned to get the logs turned right to get the most boards. I can turn out plenty of lumber now.”

The chamfer edge angle is the angle between the chamfer face and the support face. (This is the angle you specify while modeling a chamfer in SOLIDWORKS.)

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Consider a project where the cutter is engaged in the material accelerating at 100 inches per minute along a linear path. When it comes to a 90-degree corner, the cutter must decelerate to a dead stop precisely at the corner point, change directions, and accelerate back up to 100 inches per minute to continue cutting. This rapid deceleration results in increased torque loads on the machine.

As he talks Leonard uses a long peavey pole that he hooks under a huge fir and effortlessly rolls off the skids onto the carriage. “If it’s got fuel and a spark plug I probably have torn it apart.”

When he shuts off the engines for a break, I ask Leonard about his favourite wood to mill. “I love hemlock, nice to cut and works so straight,” he says. “Cedar is good too. Mostly I mill spruce and fir with a bit of beech or maple, but very little. I hate tamarack, it’s so awful twisted and crooked and a real job. I hate it, but I’ll cut it.”

Feed rate can also contribute to the wear on your CNC machine components over time, which is what makes feed rate optimization so important. More on that later.