Slide 003: Machine Pre-Flight & Job Setup Procedure

Slide Visual

Slide Overview

This slide presents the complete step-by-step procedure for setting up a CNC router job, from power-on through the first cut. Following a consistent setup procedure prevents the most common errors and ensures safe, accurate operation.

Instruction Notes

The Setup Procedure (14 Steps)

Phase 1: Machine Inspection (Before Power-On) 1. Clear the bed: Remove all tools, clamps, debris, and materials from previous jobs 2. Inspect the spoilboard: Check for excessive grooves, warping, or damage. Resurface if needed 3. Check dust collection: Verify hose connections are secure, dust boot is attached, and the collector/filter is not full 4. Inspect the bit: Check for dullness (shiny edge = dull), chips, or damage. Replace if needed 5. Verify collet condition: Inspect for scoring, contamination, or deformation

Phase 2: Material & Workholding Setup 6. Position the material: Place stock on the spoilboard, aligned to the machine's axes (use a square against a reference edge if needed) 7. Apply workholding: Secure with chosen method (clamps, screws, tape, vacuum). Test hold by pushing firmly on the material — it should not shift at all 8. Document clamp positions: Note clamp locations relative to the toolpath for Z-clearance verification

Phase 3: Machine Power-Up & Zeroing 9. Power on and home: Turn on the machine, controller, and spindle power supply. Execute the homing sequence (Z first, then X/Y) 10. Install the cutting tool: Follow proper collet/bit installation procedure (see Slide 002) 11. Set X/Y zero: Jog to the appropriate corner of the material and zero the X and Y axes in the work coordinate system 12. Set Z zero: Use the touch plate or paper method to set Z zero at the material surface

Phase 4: Pre-Cut Verification 13. Load and preview the G-code: Open the file in the controller software. Verify: - File name matches the current job - Toolpath visualization fits within the material boundary - No toolpath lines cross clamp positions - Estimated cycle time is reasonable 14. Air cut test (optional but recommended for new jobs): Run the program with the spindle OFF and Z raised 1" above actual zero. Watch the full toolpath to verify XY movements are correct

The First Cut Protocol

When starting a new or unfamiliar job: - Start with feed override at 50% and increase gradually as you confirm the cut looks and sounds correct - Keep one hand near the E-stop for the first minute - Listen for chattering, squealing, or changes in spindle sound - Watch for chip formation — good chips indicate correct parameters - Monitor for material movement — any shifting requires immediate E-stop

Common Setup Errors

Error	Consequence	Prevention
Wrong Z-zero (spoilboard vs. material surface)	Cuts too deep, damages spoilboard/table	Always verify Z-zero method matches CAM setup
Forgot to tighten collet	Tool pulls out during cutting	Two-wrench tightening, pull test
Clamp in toolpath	Collision, broken tool, launched clamp	Preview toolpath over physical setup
Wrong file loaded	Cuts wrong program	Verify filename and preview before cutting
Dust collection off	Health hazard, visibility reduced	Add to pre-flight checklist

Key Talking Points

1. A consistent setup procedure prevents 90% of CNC incidents
2. The air cut test catches errors that simulation cannot — it verifies the physical setup
3. Never rush the setup — time saved by skipping steps is lost to crashes and rework
4. Feed override at 50% for the first cut is not optional for new jobs
5. If anything looks or sounds wrong, press E-stop first, diagnose second

Learning Objectives (Concept Check)

• [ ] List the 14 steps of the complete job setup procedure in order
• [ ] Explain the purpose and procedure of an air cut test
• [ ] Identify the 5 most common setup errors and their prevention

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Last Updated: 2026-03-19