Router problems

A couple of considerations:

  • it’s not really possible to “baby” a cut — that just leads to rubbing because the machine isn’t advancing enough to form a complete chip — feeds and speeds need to be adjusted in synch so as to maintain chipload, see:
  • avoid slotting — cutting a slot just as narrow as the tool results in near constant high tooling engagement which makes a cut far more difficult and results in awful noises — where possible avoid slotting and add geometry and cut as a pocket

and/or

and consider leaving a roughing clearance and taking a finishing pass.