Gerry,
I'm using 1/4" bits, and whatever RPM the new PC690 routers spin at, they're no longer variable rpm. I always cut them at max rpm on my other hand router anyway because they slow down too much if I don't. And on the CNC, cutting at around 30ipm.
Steve - I've never heard of this resonance issue. I'll give that a go tomorrow. I usually jog a while anyway when setting up new pieces, and havn't noticed anything. What are these dampers you speak of? And did you notice similar results in your cutting when this happened?
I did tweak the machine today. I went out and checked all my set screws, everything was good and tight. I loosened my x axis (single motor) pre-load adjustable springs, in case it was putting too much load on the motor, and then I added some springs to each motor on the y axis for a pre-load against the rack. Before I just had screws tightened down, and I was always afraid the rack was slightly bowed in some areas because of the welds which would cause backlash. This should help the situation, although I may need to go get tighter springs.
I'll see if anything had an effect tomorrow as I have more letters to cut. Hope they turn out nicer than my other ones! I keep getting tempted to just do vinyl and quit cutting letters because I get nervous selling things I'm unsure if I will be able to cut (I have a very quick turn around time on most items), but I have too much money wrapped up in it and really enjoy my CNC!
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