Machine Bogs Down During Milling

Machine Bogs Down During Milling

When the Ghost Gunner 3 bogs down in a pocket milling operation, these are the likely causes.  Check to ensure that these are not applicable to your situation. 

1.  Hard limit error prior to trigger hole milling operation

a.  When the spindle retracts, the z limit switch may be tripped. This occurs if adequate material is not removed during a milling operation. This is normally caused by chip buildup. 

2.  Correct tool

a. Using an alternative end mill will likely result in the cutting tool bogging down during the pocket milling operation.

3.  Secure Collet Nut

a.  Make sure the collet is properly seated into the collet nut. The collet should snap into the collet nut when turned at a 45-degree angle so that the collet and nut do not come apart. Slide the tool into the collet-nut assembly. Thread the tool-collet-nut assembly onto the spindle. Push the tool all the way into the spindle then tighten the collet nut to ensure that the tool does not walk out while milling. The collet should not be able to fall out of the collet nut once snapped together.

4.  Secure Jig

a.  Tighten the mounting bolts so that the lower is securely attached to the t-slot plate. Tighten the jig and lower assembly very tight but not so tight that it deforms the jigs. The jigs should snap in firmly to the lower without bending or deforming. The lower should sit level on the t-slot plate. Take care when tightening the magazine well jig piece to not push the back of the lower too far down. Tighten the small bolts for the left and right jig piece, then tighten the mag well jig bolt.

5.  Reduce Chip Buildup

a.  Excessive chip buildup can lead to bogging down during the pocket milling operation and leave a rough finish in the pocket. Leaning the machine back a few degrees by propping up the front can greatly improve chip removal. Vacuuming periodically or if you notice a large buildup of chip can help to prevent bogging down due to chip overload.

6.  Dull Tool

a.  A dull tool may fail to remove an adequate amount of material. The recommended ¼” custom carbide end mill typically begins to show signs of wear after completing around eight AR lowers. This means that it may be time to get another. Always examine tooling for signs of wear prior to running a cutting program. Using an alternative end mill will likely result in the cutting tool bogging down during the pocket milling operation. 

Always observe the machine while running cutting programs. Abort the program if you notice a problem in the milling operation.

Spare tooling is available on our product page. https://ghostgunner.net/featured-products/#tooling 

The bottom foam pad that the Ghost Gunner comes shipped in is useful for reducing resonance vibration during cuts. Placing the machine on the floor or otherwise resting it on a large surface can reduce vibrations and improve precision.