I dabble a little in wood now and then, but I'm mostly a metal guy.
I unfortunately have a project that requires me to produce a large
number (hundreds) of nominal 1.5" - 2" dia x .5" - .625" thick wood
disks probably from a decent hardwood. End grain should be on the side
of the disk.
I need to figure out a way to produce these disks in an efficient manner
and with good surface finishes. They can't have a center hole. A regular
hole saw (without the usual pilot drill) in my mill gives a lousy finish
on the outside of the disk and very inefficient disk removal from the
Any single point cutter like the adjustable circle cutters or a CNC
router will mangle the disk when it breaks free at the bottom of the cut
without an elaborate vacuum clamping system. Leaving the cut just shy of
the bottom and then running the sheet through a thickness planer might
free the pieces, but I'm not sure that a thickness planer can handle
feeding the loose 1.5" pieces on the outfeed and keeping them from
flying up into the cutter.
I see all sorts of cheap little wooden toy wheels and whatnot so there
has to be an efficient way to produce these, but I'm not sure what it