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Weird Wear On Toolholders and Spindle, What Could be the Cause?

6/28/22       
Benjamin Rogers Member

Website: https://www.olympiccnc.com/

I bought this CNC router new (Freedom Machine Tool, 5x10, 10hp Hiteco Spindle) about 18 months ago.
Early on, the tool holders and spindle taper started to show a lot of "fretting" wear, which seems to be caused by excessive vibration between the tapers, see the attached photos.
I don't have a ton of hours running the machine, it runs 1 or 2 days a week.
I've tried to diagnose the problem, and my current theory is that it's a simple feed/speed issue, but I wanted to get your opinions on it.
I use 3/8" Amana down-spiral router bits, cutting 3/4" plywood at 300ipm, 18000 rpms, and around 0.7" depth of cut (I cut in 2 passes, a rough and finish).
According to the Amana spec sheet, this feedrate is a little high, but the machine handles it without any issue and I've never broken a tool.
Are these feeds & speeds unreasonable? And could they be the cause of this crazy fretting, or should I look elsewhere?

This issue is causing me so much stress, if anyone has any input or ideas it would be highly appreciated.

Thank you.


View higher quality, full size image (4032 X 3024)


View higher quality, full size image (4032 X 3024)


View higher quality, full size image (4032 X 3024)

6/28/22       #2: Weird Wear On Toolholders and Spind ...
Tom Gardiner

The feeds are acceptable for the machine in my opinion. In fact I would slow down the rpms to 16k. You don't want to hear screaming from the bit.
As for the fretting corrosion, first I would clean the corrosion from the spindle socket and holders with scotchbrite. It will not distort the cone dimensions significantly. The corrosion is actually decreasing the taper diameter. There's lots of discussion about whether to lubricate the spindle taper and with what online with machine shops. Does this apply for wood working machinery? What you may be experiencing is flash corrosion from high humidity. Oil or grease will help with that. I just worry that it wil attract dust that will get trapped between the tool holder and taper.

6/29/22       #3: Weird Wear On Toolholders and Spind ...
BH Davis  Member

Website: http://www.bhdavis.net

Your feeds and speeds seem fine to me. That's about what I have always run on similar materials.

I think you are getting the corrosion on the bottom of the spindle taper and that is transferring to your tool holders. As suggested gently clean it all with red a Scotchbrite pad. You can spin the spindle at a very low rpm and hold the pad in place with a dowel or something similar if you don't have a taper cleaning tool.

Then you can try applying a touch of paste wax or anti-seize to the bottom 1/2" of the spindle taper and see if that prevents the rust from reoccurring. Anti-seize is a good option for this but is quite messy. Maybe a better choice though for testing.

I regularly cleaned my spindle taper and tool holders this way to keep them clean. Your problem is not unusual.

BH Davis

6/29/22       #4: Weird Wear On Toolholders and Spind ...
cris

Thats rust. Are you running an air dryer?

6/30/22       #5: Weird Wear On Toolholders and Spind ...
Dylan Bayliss  Member

Website: http://www.machineconsult.com

we sell a anti seize lubricant that could be a good fit once you removed the rust/oxidation as recommended above.
https://www.cnc-tool.com/store/p708/Metaflux_Lubricating_Metal_Spray_400mL.html#/

6/30/22       #6: Weird Wear On Toolholders and Spind ...
Marc Member

Website: http://www.t-toolusa.com

Definitely clean the rust off as suggested and an anti-seize lubricant might be your best bet. Cover the spindle nose after use as it seems you may have some moisture buildup.

7/3/22       #7: Weird Wear On Toolholders and Spind ...
Tom Gardiner

I looked at the photos finally on a larger screen and this is rust. Fretting is typically more black in colour and less evenly distributed.
Moisture can be from a few issues. It could be in your compressed air supply as was suggested. It can be atmospheric if you live in a high humidity area or it can be coming from your sheet goods. I have routed mdf and ply that has raised the cut line on my spoilboard from the water vapour condensing on the relatively cool spoilboard all from the workpiece.

7/5/22       #8: Weird Wear On Toolholders and Spind ...
Acctek  Member

Website: https://www.acctekgroup.com/index.html

Observe the accuracy of the machined parts and the chip marks on the surface of the parts, so as to judge whether the tool holder is locked and whether the repeated positioning is good. Replace the spindle. The replacement method should refer to the spindle description of the corresponding tool holder model. Do not change the size of the spindle at will, otherwise it will seriously affect the service life of the tool holder.

7/20/22       #9: Weird Wear On Toolholders and Spind ...
DannyB Member

This looks like rust being caused by the pressurization air being too wet (or something like that)

You could just test it to see for sure, but fretting of on metal would not be this color for these parts - it would be blackish.


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