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I use Vortex 3/8" compression bits for most of my CNC cutting. My machine is old, slow, and I gave up on the vacuum and simply use screws at the corners now. So, for 3/4" sheets I do 2 passes, the first at 1/2" and the second a through cut.
My problem is that I end up with a line on my parts at that 1/2" initial depth cut after just a few sheets with a new bit. I'm sure part of the problem is that my feed rate is too slow. But my machine (Digital Tool) isn't designed to run as fast as the feed rate should be. So, aside from bumping up my feed rate, is there any setting in MasterCAM I could use to improve my cut results and/or get better life out of my tools?
What is your feed speed? Cutting is all about finding the appropriate chipload for the cutting edge. If you can't speed up the feed speed, try slowing down the rpm of the spindle.
You have a couple of unique problems.
A bad lead in/lead out can cause a dead spot in a bit, which I believe is what you're saying you have. That and a lack of rigidity of your parts will wear them out quickly as well. Had seen similar issues on a old multicam a few years ago that ran painfully slow compared to my new scm universal 20. He was using less aggressive cutters. I can't recall the number but it was a basic onsrud cutter...