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PANEL PRO
Use only high quality high strength end mills. Such as Metal Removal PN 159-3453-
27 (M30293) or Atrax PN 85297083 supplied in started kit. The preferred end mill
is the double ended 1/8” end mill with the 3/16 shank.
Bit breaks when the interior slug parts from the parent metal. Use a lead in line
length greater than 0, set in options > lead in line length. Never use single ended
end mills other than the M30293. Other single ended end mills are not strong
enough and will break in short order.
Bit is chipped or dull, taking excessive cutting force. Even a very minor chip on the
cutting edge will result in deteriorated cut finish and accuracy.
Excessive feed rate. A normal feed rate for 1/8” 2024 T3 is around 12” per minute.
Cutting material that is too thick. Any thing thicker than.125 aluminum should be cut
with multiple passes not exceeding .125 per pass, removing chips from the slots
between passes. A good coolant flow will help remove the chips.
Moving and running into obstacles without the router running.
End mill is not secure in the collet allowing the end mill to slip down to the non
cutting area on the shank. The router will sound like it is laboring.
Improper volume or maladjusted coolant. The end mill must be lubricated to avoid
material build up, and chips must be flushed away.
If an end mill has broken inside the collet, it may have left a burr. Run a 1/8” fine file
through the collet to remove burrs.
Inside dimensions are too small:
End mill chipped or dull.
A normal cut is usually about .001 to .002 smaller than drawn.
Finish cut should be checked.
Using excessive cutting speed
Using wrong end mill size on the cut dialog.
If only the x or y dimension is too small suspect backlash or loose parts. Also make
sure that the motor to lead screw coupler is not broken or loose.
Inside dimensions too large:
End mill is bent or crooked in collet
Wrong end mill size specified on the cut dialog.
Make sure collet is clean.
Outside dimensions too large:
Verify “use holding nibs” is checked on the cut dialog.
Finish poor:
Make sure work is clamped securely so it cannot move vertically or horizontally.
