ONSRUD DIVISION Dan ly Machine Corporation

2100 South Laramie Avenue, Chicago, Illinois 60650 312/242-1800

MODEL W1124 ROUTER

ROUTER CUTTING GUIDE

Form RCG- 4/15/77

OPERATIONS PERFORMED WITH PIN TYPE ROUTER

1. MOULDING A. STRAIGHT LINE

(1) WITH A FENCE B. CURVED OR CONTOUR LINE

(1) WITH A GUIDE PIN TO A PATTERN EDGE. (2) WITH A PILOT ROUTER BIT TO A PATTERN EDGE.

c. RECESSED (1) WITH A GUIDE PIN & PATTERN

2. MORTISING A. STRAIGHT LINE

(1) WITH A FENCE (2) WITH A FENCE AGAINST STOPS

3. SHAPING A. STRAIGHT LINE

(1) WITH A FENCE B. IRREGULAR

(1) WITH A GUIDE PIN TO A PATTERN EDGE.

4. VEINING A. ANY DESIGN

(1) WITH A GUIDE PIN TO A PATTERN.

5. RECESSING A. ANY DESIGN

(1) WITH A GUIDE PIN TO A PATTERN.

6. DADOING (GROOVING) A. STRAIGHT LINE

(1) WITH A FENCE

7. TENONING A. STRAIGHT

(1) WITH A FENCE

8. BORING A. HOLE PUNCHING ROUTER BITS.

9. 'RABBETING A. STRAIGHT

(1) WITH A FENCE

10. DOVETAILING A. STRAIGHT

(1) WITH A FENCE OR A JIG.

11. VENEER TRIMMING A. WITH A GUIDE PIN TO A PATTERN EDGE. B. WITH A PILOT ROUTER BIT TO A PATTERN EDGE.

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PIN ROUTER (FLOOR STAND TYPE)

The router is a versatile machine which can make a large variety of cuts, one of which is to cut mortises. The use of a router to cut mortises will be discussed first, the other uses afterwards.

Cutter

In cutting mortises with a router, the cutter looks like Figure I. Some cutters have 2 cutting edges like Figure I-A, some have 1 cutting edge like Figure I-B.

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A Figure I. B

These cutters are clamped in a chuck on the end of a spindle which turns at high RPM. If the cutter is pushed endways into some stock it will bore a hole like a bor­ing bit. But boring bits do not have cutting edges on the side, whereas the above router cutters do. Consequently a boring bit can only bore a round hole. But if a router cutter is sunk into the stock and the stock is then moved against the side of the router cutter, the cutter will cut on its side and can make a cut like Figure II. This gives a mortise type of hole. The depth A depends on how deep the cutter is sunk into the stock. The width B depends on the diameter of the cutting circle of the cutter. The length C depends on how far the stock is moved while the cutter is sunk into the stock.

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SIDE VIEW

Machine

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TOP VIEW Figure n.

Figure III shows a typical router. In operation of this model, the table (1) is adjusted vertically to desired height and the spindle (2) is lowered toward the table by means of an air foot pedal (3). Depth of the cut is controlled by a depth stop (4) which can be adjusted by the operator.

For cutting mortises a fence type set up is generally used very similar to the fence set up on a shaper. The guide pin (5) is removed and a straight fence is clamp­ed onto the table. The width of the mortise is obtained by mounting the right diame­ter of cutter into the spindle. The depth of the mortise is obtained by setting the depth stop. The distance of the mortise from the edge of the stock is controlled by the distance from the fence to the cutter. The position of the mortise from the end

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CONSTRUCTION FEATURES I SERIES 1100-.A ROUTER

AUTOMATIC Alemite Lubrication­for positive and continuous bearin& lubrication ... fine oil mist "bathes" spindle and spindle bearin&s when router is in operation maintaining the desired operating condition to insure long bearing life.

EASY ACCESS-to top of Router. Hinged lid with locks permits fast access for adjustment and regular preventive maintenance

VISIBLE OIL SUPPLY-fast check available at all times, decreases possibility of running without oil or using contaminated oil and burning out spindle bearings.

MASSIVE MACHINE TOOL CONSTRUCTION-The stand, column and overarm is a large one-piece casting of Meehanite. This heavy high grade casting insures vibration­free performance without spindle deflection and permits accurate routing of all types of material from the hardest woods to all non-ferrous metals.

G) ADJUSTABLE DEPTH STOPS-easily set to stop spindle feed at any point in the 0" to 3¥• " range and provides positive repetitive depth control. Three adjustable positions with locks to insure accurate cutter depth throughout routing operations.

AIR NOZZLE-to keep work area clean is standard equipment. A special Onsrud Air-miser (optional) maintains a controlled air stream wh ich operates when spindle is lowered to work and stops when spindle is retracted. Separate controls permit use of air when otherwise required .

SQUARE EDGES ON MACHINE-GROUND TABLE

OPTIONAL TILT-TOP-adjusts to downward tilt of front edge to any position-maximum 45 ° angle .

TILTING TABLE LOCK & RELEASE­holds table position accurately and permits fast change of table area .

service.

<V AIR FOOT PEDAL-lowers and raises router head without op­erator effort. A touch of the operator's toe lowers or raises the cutter smoother, faster and more accurately. A flexible airline connection allows foot control to be moved to the op-erator's best feed position for each routing job. The operator will do more and better work in less time with less effort .

Figure III 4

PUSH BUTTON CONTROL-station is directly in front of opera-tor for convenience and safety. Has start, stop .(controls spin­dle brake)

INTERCHANGEABLE HEAD ASSEMBLIES Keeps unproductive downtime to a minimum.

G) SPINDLE STROKE--o" to 3 Y,".

<D PRECISION-GROUND TABLE-cast iron, rib-reinforced, square edged, and machined and ground true . Standard size 26" x 36" or optional 36" x 48".

G) DOUBLE-END GUIDE PIN-three sizes are supplied as standard equipment-~, .. and X ", ~.-·and Y, ", and 116' and Y," . Other sizes optional .

GUIDE PIN LOCK & RELEASE-holds guide pins securely but permits rapid change when necessary.

TABLE LOCK-holds table securely in place with a gib wedge

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after table has been adjusted vertically.

HANDWHEEL-adjusts table ver­tically. Maximum table to spin-dle distance is 13". Minimum 0". Table has a maximum vertical travel of 12" . A ball thrust bearing on the table lift screw permits fast and effortless vertical movement of the table simply by turning the handwheel.

of the stock and the length of the mortise is controlled by clamping two stop blocks to the fence. In operation, the following sequence is followed:

1. Stock is placed down on the table, with its edge against the fence, with one end against one of the stop blocks.

2. The spindle is lowered until stopped by the depth stop and is held down in this position. This bores a hole in the stock.

3. The stock is held against the fence and moved lengthways until the other end of the stock hits the second stop block. This cuts the mortise.

4. The spindle is raised and the stock is removed with the mortise all cut. Another piece of stock is placed in the machine and the cycle is repeated.

Holding and feeding of the stock is done by hand. There is no power feed.

Speeds, Feeds and Production

Router spindles run at 10, 000 or 20, 000 RPM, small diameter cutters at the higher speed.

All router work is hand fed.

Variety of jobs which can be done on a router is so large it is not possible to give general rules for production per hour.

Advantages and Limitations of Router Mortises

Regular routers are single spindle machines whereas hollow chisel mortisers are available as multiple spindle machines. Where several mortises are to be cut in a piece of stock, a hollow chisel mortiser is apt to give more production per man hour than a router.

Hollow chisels are not very satisfactory for mortises less than 1/ 2" x 1/ 2" though some are as small as 3/8" x 3/8". Router cutters are satisfactory as small as 1/ 4" or even 3/16" if the cut is not deep. But on deep cuts with small diameter cutters, the strain of cutting on the side of the cutter is liable to cause considerable breakage of the cutter. There is also considerable vibration and chatter of the cutter which results in variations in the width of the cut. In general, it is wise to use as large diameter cutters as possible for deep cuts on a router.

The top view of a hollow chisel mortise cut is a square with sharp corners ; the top view of a router mortise cut is a rectangle except that the ends of the rectangle are half circles instead of straight lines. It is easy to cut a tenon which is square or rectangular with sharp corners; but no production machine will cut a tenon with half circles as the ends of a rectangle. Consequently, a hollow chisel mortise will accurately located the tenoned piece which goes into it; whereas a router mortise will not because a straight line cut at ends of a rectangular tenon do not fit the half circle cut at the end of the mortise.

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If router mortises are not to show half circle holes after assembly, it is neces­sary to make the tenon with two passes over the tenon machine instead of one. Fig­ure IV shows this.

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ONE PASS TENON

Figure IV.

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TWO PASS TENON

The mortise still does not locate the tenoned piece accurately, but the holes are covered.

A rectangular hole can be cut with hollow chisel mortiser by taking more than one stroke. For example, with a 3/ 4" x 3/ 4" chisel and two strokes of the machine, mortises can be cut from 3/4 x 13/16" up to 3/ 4" x 1/2". Or with three strokes mortises can be cut from 3/ 4'' x 1 9/16" up to 3/ 4" x 2 1/ 4". The stock is moved in the machine between strokes. On strokes after the first, it is not necessary that the cut be 3/ 4" x 3/ 4" because the chisel can cut partly wood, partly air; so the second cut could be anything between 3/ 4" x 1/16" and 3/ 4" x 3/ 4".

ROUTERS FOR OTHER USES

Besides cutting mortises, many other types of work can be done on a router.

Figure V. Figure VI. 6

Figure V shows a straight sided cutter and fence such as would be used for a mortise cut. If stop blocks are not used, the cut would be a groove like Figure V. Or with stop blocks, a long groove could be cut stopping and starting wherever desired. As a matter of fact, a router mortise is nothing but a short router groove stopping at both ends.

If the cutter has pattern ground edges instead of straight edges, Figure VI shows the set up for shaping a straight edge.

Three types of cutter are available for cuts like Figure VI. One has a shank as part of the cutter, Figure VII-A. This shank goes into the chuck on the spindle. Another has a hole which fits over an arbor, the arbor being held in the chuck on the spindle (Figure VII-B). A third is a flat piece of knife steel (Figure Vll-C) which is held in a special chuck (Figure VII-D).

A B c D

Figure Vll.

If the edge is not straight as in Figure VI but has been bandsawn to an irregular line there are two set ups available for shaping the edge. Figure VITI-A shows a set up where the shape does not cover the whole edge. The guide pin (5), Figure Ill) is set in the machine so that it projects up beyond the face of the table. The machine is built so that the center of the guide pin is exactly in line with the center of the spindle. The circular outside face of the guide pin is therefore concentric with the cutting circle of the cutter on the spindle. Guide pins can be had in a variety of diameters. (Also see Figure VIII-A & B).

WORK

TABLE A B

Figure vm.

If the shape covers the whole edge of the stock, the bandsawn edge is made on a flat form. The stock is mounted on the form and the form runs against the gu:lde pin, Figure VIII-B. It is necessary to keep the stock from slipping on the form by spurs coming up through the form or by quick acting clamps mounted on the form.

The router can also be used to cut irregular shaped holes through flat stock in place of using a jig saw. The router is faster than the jig saw and also eliminates a preliminary operation of boring a hole for each cut out. This is needed with a jig saw in order to get the saw blade through the stock. Figure IX shows such a set up.

The stock is mounted on a form. In the bottom face of the form a groove is cut which is the size and shape of the cut out to be made. The width of the groove is just right for a slip fit over the guide pin. When the form is placed on the router table with the guide pin in the groove in the form, the form cannot move in any direction

Figure IX.

except for the guide pin to slip in the groove. As a consequence, the cutter which is mounted in the spindle makes its cut the exact size and shape of the groove in the bottom of the form. Here again, it is necessary to prevent the stock from slipping on the form by using spurs in the form or clamps mounted on it.

One other use for the router is to have a knife like Figure VII-C, hold the stock in one position on the table and lower the spindle and cutter into the stock. The re­sult will be a cut which would be a circle in the top view of the cut. But a cross section of the cut would be the reverse of the pattern to which the knife is ground. In this sort of job it is the bottom of the knife which does the cutting, not the side. Rosettes can be made this way. (See page 24)

Onsrud routers are furnished with a chip deflector and vacuum pick up hood. The operator should keep the hood on the machine for all routing operations.

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THE BASIC PRINCIPLES OF ROUTING TO PROFILED SHAPES.

CUTTER

The smallest diameter of the router cutter and the diameter of the guide pin should be the same.

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GUIDE PIN

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The component produced will then be correct in size and profile.

COMPONENT

WW~A TEMPLATE

The template should be the same profile and size as the component or article to be prod­uced.

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Cutter~

Guide pin

ROUTER JIG FOR PROFILING

Work piece

Template Hardwood rails

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.TIG FOR PROFILING

3/32" clearance

Fix hardwood rails to jig body and screw template in suitable position. It is advisable to have the jig 4" or 5" larger all round than the work piece. Fix rails and template, mark the surface of jig body by making a shallow cut with suitable size of cutter, tracing the shape of the template on the face of the jig. Cutter and former pin must be of same diameter.

Spikes ., Spacer

Having surface of jig correspondingly marked with the shape and position of template the spacer can be fixed in position.

If holding spikes are required these can be fitted. Use wood screws of suitable length to project 3/ 32" through spacer. File screw ends to a chisel edge.

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' Keep this dimensiOn as small as possible. d. 1 ,, ,

Collet nut.

Always keep the top face of the component as near to the collet nut as possible.

End cover.

Any top clamping device must be low enough to clear the end cover of router head.

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Jig for routing to shape curved components such as brush backs, etc.

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"'§::§'§:'§:'§:§:'§&~~~~~~ METHOD OF MAKING ROUTER JIGS FOR PRODUCING RECESSED BRUSH BACKS.

Prepare two jig bodies fitted with temporary hardwood rails and under each in turn pin (tack) the master sample brush back.

Mark the face of the jig with both outside profile of brush and shape of recess.

Mark face of jig.

Template material can be mounted on face of jig and cut to shape during this stage of jig making.

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FITTING TEMPLATES TO JIG BODIES.

Remove temporary rails from jig body, turn jig over and fit hardwood rails on the opposite side, that is the marked face.

Fit template firmly, locating it from the previously made markings.

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VIEW OF TEMPLATES FITTED TO JIG BODIES.

Jig for profiling and shaping 1st operation. Jig for cutting out recess, 2nd operation.

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Spikes. Locating piece. Clamp.

With templates firmly fixed the face of the jigs can be marked to show the position of templates. Fix screw for the holding spikes on the profiling jig as described on page 15 and locating piece and clamp on the recessing jig.

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TYPES OF .ITG REQUIRED FOR SHAPING SPECTACLE FRAMES ON ROUTER.

First Operation. Jig for cutting out eye pieces from rough sawn blank.

- - - -- - ----- - -- - ---Locating fence.

Clamps.

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Underside of jig showing template.

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Jig for shaping outsides of spectacle frames. Locating off previously cut eye-pieces.

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® Locating pieces.

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Many articles to be shaped on the router require machining all round, such as bag handles, coat hangers, some types of brush handles, etc. For this class of work it is advant­ageous to make a jig carrying two components.

METHOD OF OPERATING JIG:-

1.

2.

3.

Put prepared blank in position A and rout outer edge.

Move shaped blank into position B locating off previously cut edge.

Place a new blank in position A. With the jig now fully loaded a finished handle will be produced at each complete circuit of jig.

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Actual shape of template.

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THE DIMENSIONS OF ANY WORK PIECE CAN BE ENLARGED OR DECREASED ON THE SAME JIG BY USING GUIDE PINS OF LARGER OR SMALLER DIAMETER THAN THE CUTTER.

Pin larger than Cutter. 2. Pin and Cutter same size. 3. Pin smaller than Cutter.

THE SAME RESULT CAN BE OBTAINED BY USING CUTTERS OF VARYING DIAMETER.

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A. Cutter in top position and guide pin engaging first template.

B. Head lowered to second position and guide pin raised.

C. Head lowered to bottom position and guide pin raised to engage third template

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Recess of various depths such as those in Cutlery trays, Tap and Die cases, types of Brush backs, etc., can be worked by making a jig with multiple templates. Each template correspond­ing to the recess of one depth. The various depths of cut are pre-set by the variable stops on the router head.

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Finished article.

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c ) ( :::=:----) First template "A"

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( ~ ) Second template "B"

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Section across tray.

First depth.

Second depth.

Third depth.

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Details of templates for working recesses of various depths.

Third template "C"

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Routed face of wood.

Saw -rut.

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Small circular objects and wheels for toys can be made by sinking a special shaped cutter into the surface of any suitable wood.

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Saw off the routed face then the wheels will fall loose. The routing operation can then be repeated on the stock piece of wood if of suitable thickness.

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Fence

Cutter head

Plywood

Machine table

METHOD OF SCARFING PLYWOOD, ETC., ON AN ONSRUD ROUTER.

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Type of jig required for shaping and moulding curved chair backs, etc.

Shaped table clamped to router table.

Cradle to carry curved chair back.

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·~ Guide pin

Front of router table.

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this side.

Simple type of pressure fence to enable small mouldings, beads, etc., and thicknessing to be worked on Router.

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Pressure fence.

Position of cutter.

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Fixed fence.

Board carrying fences clamped to router table. ·

Front of machine .

WOODWORKING

THOMPSON VACUUM CHUCKS are available in square, round and special shapes to suit individual requirements.

A shield being completely routed to a pattern on a Thompson Vacuum Chuck

OUTSIDE ROUTING

INSIDE ROUTING

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: WORK PIECE (: : '"'- - - -- - - - - - - - - _v_,

VACUUM CHUCK

TEMPLATE

Arrangement of THOMPSON VACUUM CHUCKS when used with template for various patterns and profiles.

VACUUM CHUCKS

Note textured surface, grooving and cushioned seals. Vacuum pressure is distributed over entire area of chuck.

Typical Hook-up Drawing shows the basic simplicity of a typical Thompson Vacuum System. Components are easily installed on new or existing equipment. Self-con­tained motor driven vacuum pump, collection tank, vacuum gauge and control valve can be convenient­ly located. Standard ~" air hose and ~" pipe connections are used.

The above information courtesy of the THOMPSON VACUUM COMPANY

GENERAL OFFICES AND PlANT: THOMPSON VACUUM COMPANY ESTABLISHED 1952

2187 12th Street, SARASOTA, FLORiDA 33577, Phone 813/958-0960 27

28

Breakage due to many factors ... Breakage of router bits is not necessarily the fault

of the router bit. Assuming a router bit may be properly made and constructed, also correctly tempered, which is no exception to normalcy, with uniformity in alloy of present day high speed steels and automatic recording heat treatment. High speed steel router bits properly tempered and drawn should test 62 to 63 Rockwell hard­ness, C Scale.

If the proper rake and clearance is not ground, · the bit will have a tendency to ride the cut and from th~ undue friction, heat is generated causing cutter to have a burning action and accumulate sap and dust.

The bit may not have a keen cutting edge; in that event, the cutting is as difficult as whittling wood with a dull knife. Therefore, it is imperative that in order to get maximum performance from router bits a keen cutting edge properly ground should be maintained.

Often caused by chuck or collet . • •

Assuming the router cutter is correctly made and breakage still occurs, the cause may many times be found in the chuck or the collet. The collet may not be

seating properly so that it runs out, that is, not concentric wi~h the spindle; also collet may be perfect but run out is caused by accumulation of dirt and dust preventing it from seating properly in both chuck nut and in tapered bore of spindle. The inside or bore of collet may be clean but through wear it has become egg or bell shaped; if this con-dition prevails, the bit is held only at one point and in moving the work through the cutter, a weaving or whipping action takes place in the router bit causing it to snap from fatigue or crystallization. This action is best illustrated by taking

a length of wire and repeated! y flexing or bending same until the break occurs; imagine the rapidity of this pro­cess at 20, 000 R. P.M. (spindle speed). If a router bit is not properly made - that is, if shanks are not perfectly round or made over­size or undersize in relation to standard collet bore- no bit or cutter, regardless of make, can be held so as to run true and per­form efficiently.

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Another cause of trouble is that if collet bore is not up to standard and i:s either un­dersize or oversize in relation to standard bit sizes so that shank is held either at the lower or higher point of the collet. In any event, if bit is not properly held in the collet when material is fed to same, it will flex or '

bend first in one direction and then another until .eventual breakage occurs from this undue strain.

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Your machine may be at fault ... Assuming that the bit and the collet be perfect as to

manufacture and specifications, it has often been found that a machine can be the source of trouble causing bit 29

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30

El breakage. The spindle may be inaccurately made or the ball bearing in whi.ch the spindle ro­tates may be worn. To check for this cause of bit breakage, the following procedure must be followed: Press spindle in

ROUTER BIT

bearings to check for side or end play. If any, the cause should be corrected at once. Turning the spindle by hand, contact with the bearing balls should be carefully noted.

Any tendency to catch when rotating the spindle is an indication that the bearing is defective and should be replaced at once. Place an indicator on the router table. If the spindle has an inside taper, the indicator will show whether or not this surface is out of round due to defective mach-1n1ng or wear. The outside surface

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FIG. J

of the spindle should also be checked with indicator. When doing this, the chuck or adapter should be removed. Next place adapter on spindle. In this case, again check all points which might lead to eccentricity. Thread chuck coll~t to spindle; this should be snug fit, not too tight, not too loose. This part also should be concentric with both adapt­er and spindle. Next, insert collet in adapter. This part

should be free from dirt, grit or dust.

Place in the collet a hardened and ground testing rod; it should protrude from the collet about 2". Place indicator against this rod and check for concentricity; a run

out or variance here of plus or minus of 2 thousandths may be allowable. lf more, cause should be determined and corrected.

Or your operator ...

Now assum1ng that both router bit and machine have perfect alignment, router bit

breakage can occur through ignorance of the operator as to the technique of routing operations.

Feeding the work to a router bit or cutter is no different in this respect than feeding to a saw blade. The router bit or the blade must be fed in such a manner so that in moving through the work it has a chance to bite or cut its way freely; the feel of the operator should be such that a constant and even pressure of the material into the bit or the cutter is maintained. If the material is fed too fast, an undue strain is against the router bit; if fed too slowly, friction of the bit in the material is bound to occur. Both faults are injur­ious to the life of the router bit and very common causes of breakage and failure of router bits to perform correctly.

When reversing direction of cut in routing, movement must be such that the least amount of jar or strain occurs; it must be remembered that there is a certain amount of spring in the bit when feeding work to it. When reversing or changing direction of feed, some flexing of the bit is bound to occur; however, as mentioned before, this should be kept to a minimum. In this same vein of thought, if a cutter feeds hard because of a dulled edge or hard spot due to a knot, etc. , do not take a "running start" to get moment­um. This would be a certain procedure for breakage.

CAUTION-As to the length of the cutting edge of router bits, it has been found that to get the maximum service out of high speed

steel router bits, the cutting edge as a rule should not be more than three times the diameter. There­fore, for example, a 1/4" bit should have not more than a 3/4" cutting edge; a 5/16" dia. should be 1" long; a 3/8" dia. 1-1/8" long, etc. When bits with longer cutting edges must be used, in relation to its dia­meter ,careful feeding and minute attention to the foregoing must be exercised, other­wise an increase in bit breakage is to be expected. Other methods to accomplish deep cuts are to take two or more cuts in depth or a tapered bit may be used. In the

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latter case, the bit diameter diminishes X

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from shank to tip. Up to 50% greater length can be used, with assurance of non-breakage, by means of tapered bits. 31

ONSRUD DIVISION Dan ly Machine Corporation

2100 South Laramie Avenue, Chicago, Illinois 60650 312/242-1800

THESE ARE YOUR EXCLUSIVE ONSRUD ROUTER FEATURES

- Seller certifies that equipment furnished hereunder is in com-pliance with the Occupational Health and Safety Act of 1970 (Public Law 91-596) where applicable to the manufacturer, and to the likewise applicable regulations and standards promul­gated thereunder.

- Conforms to applicable standards established by the Joint Industry Conference, the NMTBA, NEMA, NEC, and includes a "locking" disconnect switch per OSHA.

- Idle decible sound reading is 85dB(A)

- Foot pedal is housed in accordance with OSHA standards.

- Spindle brake and controls on face panel. (OSHA)

- Spindle selector switch positioned on electric panel door for safety.

- Lightest touch "Floating Spindle" of any.

- Best operator visibility.

- Dust proof pulley housing.

- The only 10 HP Router available on the market today.

- Alemite "Automatic" lubrication.

- Only operator "Training Manual" around.

- Award winning Service 1-!anual.

- Operator "Training" film available.

- Chip Deflector and vacuum pick up hood furnished as standard equipment.

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