Activity 002: Complete Job Setup β From Power-On to First Cut¶
Activity ID: U4M3-ACT-002 Duration: 40 minutes Objective: Students will perform the complete CNC router setup procedure from power-on through the first cut, following the 14-step pre-flight checklist. Group Size: 2 students (one operator, one safety observer β swap roles halfway)
Overview¶
This is the capstone hands-on activity for machine setup. Each student will independently perform the full setup procedure on the CNC router, execute a simple test cut, and verify the result. The safety observer role ensures accountability and builds the habit of crew-based safety monitoring.
Materials & Equipment Needed¶
- CNC router
- ΒΌ" 2-flute upcut end mill
- Pre-programmed G-code file: "setup_test_square.nc" (cuts a 4" Γ 4" square pocket, 0.25" deep)
- ΒΎ" MDF scrap, minimum 8" Γ 8"
- Double-sided tape or clamps
- Touch plate for Z-zeroing
- Calipers or ruler
- Setup checklist worksheet (printed)
- PPE: Safety glasses, hearing protection, dust mask
Instructions & Procedure¶
Phase 1: Student A β Full Setup (18 minutes)
Machine Inspection (3 minutes) 1. Clear the bed of all materials and debris 2. Inspect the spoilboard condition β note any issues on the checklist 3. Verify dust collection is connected and operational 4. Inspect the end mill for damage; confirm correct size (ΒΌ")
Material & Workholding (4 minutes) 5. Position the MDF on the spoilboard, square to the machine axes 6. Secure with chosen workholding method (tape or clamps) 7. Test hold by pushing firmly on all edges β material must not shift 8. If using clamps, verify they are outside the 5" Γ 5" toolpath boundary
Power-Up & Zeroing (5 minutes) 9. Power on machine and controller 10. Execute homing sequence β verify Z homes first 11. Install the ΒΌ" end mill in the collet β proper depth, two-wrench tightening 12. Set X/Y zero at front-left corner of the material 13. Set Z zero using touch plate on material surface
Pre-Cut Verification (3 minutes) 14. Load "setup_test_square.nc" in controller software 15. Preview toolpath β verify 4" square fits within material, no clamp conflicts 16. Confirm feeds, speeds, and depth match expectations 17. Safety observer verifies: PPE on, E-stop accessible, dust collection running
First Cut (3 minutes) 18. Start spindle, begin program at 50% feed override 19. Monitor first pass β confirm correct depth, good chip formation 20. Increase to 100% feed override after first pass if everything looks good 21. Complete the cut; stop spindle; wait for full stop
Phase 2: Measurement & Verification (4 minutes) 1. Remove the workpiece from the machine 2. Measure the pocket dimensions with calipers: - Width (should be 4.000" Β± 0.010") - Length (should be 4.000" Β± 0.010") - Depth (should be 0.250" Β± 0.005") 3. Record measurements on the checklist 4. Note the surface finish quality (smooth, rough, burn marks, tearout)
Phase 3: Student B β Full Setup (18 minutes) Repeat Phase 1 and Phase 2 with roles swapped.
Discussion Points¶
- How did your measurements compare to the programmed dimensions? What might cause discrepancies?
- Did the safety observer catch anything the operator missed?
- What step in the procedure felt most uncertain? How would you build confidence?
- How would the procedure change if you were cutting aluminum instead of MDF?
Expected Outcomes¶
- Both students complete the full setup procedure independently
- Cut dimensions are within Β±0.010" of programmed values
- Students demonstrate correct safety protocol throughout
- Safety observer identifies at least one potential issue or reminder
Assessment Rubric¶
| Criteria | Excellent (4) | Proficient (3) | Developing (2) | Beginning (1) |
|---|---|---|---|---|
| Procedure Compliance | All 14 steps completed in order without omission | All steps completed with minor sequencing issues | Most steps completed, some skipped | Cannot complete procedure independently |
| Z-Zero Accuracy | Measured depth within Β±0.005" of programmed | Within Β±0.010" | Within Β±0.020" | Greater than Β±0.020" error |
| Dimensional Accuracy | X/Y within Β±0.010" | Within Β±0.015" | Within Β±0.025" | Greater than Β±0.025" error |
| Safety Observer Role | Proactive identification of potential issues | Monitors attentively, catches errors | Passive observation | Does not engage in observer role |
Safety Considerations¶
- Both operator and safety observer must wear full PPE during powered operation
- Safety observer must have clear access to the E-stop at all times
- Never reach into the cutting area while the spindle is running
- If the material shows any sign of shifting, press E-stop immediately
- After the cut, wait for the spindle to stop completely before approaching
Last Updated: 2026-03-19