806 INTRODUCTION TO MANUFACTURING (Goodwin) Unit 5: Introduction to CNC Machining

Lesson 1: CNC a Wood Plaque

Duration of Days: 5

Lesson Objective

Students will be able to utilize Fusion 360's CAM workspace to generate 2D and 3D toolpaths, set up a Tormach CNC machine (workholding and zeroing), and safely manufacture a custom wooden plaque from a digital design.

What is the difference between CAD (Drawing) and CAM (Programming)?
Why do we need different "feeds and speeds" for cutting wood versus cutting metal?
How does the "Setup" in the software relate to the physical "Setup" on the machine (where is X, Y, Z zero)?

Parametric Modeling
Orthographic Projections
Toolpaths
G-Code
CAM

MAN.04.03: Develop a plan for the production of a product (selecting tools and processes).
MAN.05.01: Create a program using G-code or CAM software to produce a part on a CNC machine.
MAN.05.02: Demonstrate the safe setup and operation of CNC equipment (milling machine).
MAN.02.01: Demonstrate the ability to work safely with machines in a manufacturing laboratory.

Description: This lesson bridges the gap between the virtual and physical worlds.
Students design a simple plaque (rectangle with text/logo) in Fusion 360. Constraints are strictly enforced (e.g., "Must fit within 4x6 inch stock").
Instruction shifts to the "Manufacturing" tab. Students learn to create a Setup (defining the stock) and apply Toolpaths (Pocketing for removing material, Contouring for cutting it out). They simulate the cut to check for collisions.
Students rotate through the machine. They clamp their wood, touch off the tool (Set Z-Zero), and run the program. While waiting for their turn, others are sanding and painting completed plaques.

Purpose: To understand Computer Numerical Control (CNC). This is the standard technology in modern manufacturing; this project proves that "if you can draw it, you can make it."

DOK Level:
Level 2 (Skill/Concept): Selecting the correct tool (e.g., 1/4" End Mill) for the job.
Level 3 (Strategic Thinking): Determining the most efficient machining strategy (e.g., "Should I cut the letters first or the outline first?" to maintain vacuum pressure or clamp strength).

Use the "Simulation" feature in Fusion 360 heavily. Turn on "Stock Material" visibility so they can see exactly what the virtual cutter will remove before they ever touch the real machine.

Formative: "Simulation Check." Before a student is allowed to approach the CNC machine, they must show the teacher their Fusion 360 simulation. The teacher checks for "red collisions" or rapid moves into material.

Summative: The Finished Plaque.

 

  • Rubric Criteria:

    1. Dimensional Accuracy: Is the cut depth consistent?

    2. Surface Finish: Are the edges smooth (sanded) or rough?

    3. Process Safety: Did the student follow all safety protocols (safety glasses, closed door, E-stop awareness) during the run?

 

  • Machinery: Tormach CNC Mill (or similar router).

  • Materials: Wood stock (Pine or MDF recommended for beginners), Sandpaper, Paint/Stain.

  • Tooling: 1/4" Flat End Mill (for roughing), 1/8" End Mill (for detail).

  • Software: Fusion 360.

  • Safety Gear: Safety glasses for all students in the shop area.