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Avoiding Router Tool Breakage Issues
Avoiding Router Tool Breakage Issues
We all need to know this whether we are DIY or a skilled pro - it will save you money and maybe just maybe your eyes or fingers.
Router tool failure is caused by many reasons but the main one is Collet Wear - This is the cause of over 95% of tooling breakage.
If cutter the shows signs of 'fretting' brown marks on the shank of a router cutter are a sign of worn collets. The brown stain is caused by vibration that occurs during the cutting cycle.
The cutting cycle involves the collet continually heating up and cooling, being tightened up and loosened this leads to metal fatigue and the collet gripping incorrectly.
The collet fails to grip the shank correctly and causes the vibration. (The collet grips only on two or three sides) The vibration that this causes, if allowed to continue will cause the tool to shear.
The only solution is to replace the collet. This option is far cheaper than replacing tool after tool.
Collets should be kept clean and free from resin, use brass collets brushes each time to remove the tool. These can be bought from most saw doctor's router suppliers.
Choice of tooling
Tooling choice is as important as the wood you are cutting so choosing a cutter to suit the application is the second most common cause of tooling failure.
Choosing a router cutter to "make do" can and normally does end up costing you more. Not using the tool correctly –a 50mm length of cut tool and only using the bottom 4-5mm of the tool. This will put undue pressure on the bottom of the tool and once again lead to breakage. A router bit with the smallest length of cut should be used to avoid breakage. So if you only have a 4mm deep slot to rout in the choose a cutter with a 6mm length of cut(LOC) If this cannot be avoided the cut as close to the shank as possible. Remember a snapped in your work piece can end up costing more than the tool you should have bought.
Cheap Tooling
Cheap Tooling as we know is very appealing, especially when times are tough but it is something worth looking into. If you have a repeat job with hundreds of metres to cut the only option worth considering is a good quality industrial cutter.(such as Trend or Titman) If you have a job that you have a fair bit to do then choose a midrange tool.(Freud, CMT or Trend Trade Range)
As some have mentioned in the past, you do get what you pay for so if you only have say a run of 2 metres why would you pay the earth so it is worth weighing up the cheap imports.(eg Trend craft range) but be warned a lot of the cheapest cutters available are poorly made, unbalanced and use very poor tungsten carbide.
And here's one for you CNC boys out there – Start the machine spinning before you feed the tooling in! I have seen 25mm diameter tools bent at a 90 degree angle that were sent back as faulty!!
It's easy to blame the tool when all goes wrong.
About the Author
I have been in the router manufacture business for over 17 years and hope I can help.
Fix your Shanks! #1 Most Popular Teacher on You Tube Shawn Clement