Feed rate, RPM, depth of cut, not enough rigidity in your router frame. All
those can cause chatter marks like that. Could be flex in the table or the MDF
isn't secured well enough. How is it held down?
What is the recommended chip load per tooth for the cutter you are using? Its
manufacturer should have that data. Google mdf feed speed calculator
If you're breaking cutters you are pushing something too hard/fast. 1/2" thick
MDF in a single pass with a 1/4" cutter is a tough job. You might find you can
make the cuts faster in two higher speed passes than in one full depth pass at
a lower feed rate.
From: Todd Zuercher <[email protected]>
To: Enhanced Machine Controller (EMC) <[email protected]>
Sent: Tuesday, May 24, 2016 8:14 AM
Subject: [Emc-users] Tool Marks?
Anyone know the root cause of tool marks like this? Or better yet how to
prevent them? The lines are not in a straight line or consistent angle, in fact
there are places on this piece where they wave up and down.
The tool is a 1/4inch solid carbide down spiral, cutting at 200ipm turning
17,000rpm cutting 1/2" MDF in a single pass. In the picture you can see about a
half inch long section of the cut where the cut is nice and smooth, this is
where the ramp in point is (start of the cut). The machine is a very large
(5ftx10ft) moving table fixed bridge commercial router (Komo) with a 14KW
spindle and HSK63F tooling.
It does kind of give the piece a sort of simulated wood grain look. I've
playing with the amount of tool sticking out of the collet can make it better
or worse, finding the sweet spot is a bit of trial and error, and 0.050 can
make a big difference. You can hear the difference in the sound when you get it
right, the cut is very quiet. If it gets bad enough the tool will snap. Also
playing with the RPM can somtimes make it better.
It is hard to believe that a carbide tool or collet could flex that much, but
something sure seems to be vibrating.
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