Roland DWX-42W issues with rough milling bur

[TKTECH97]

Sorry for the vague title but I'm running the Roland 42w wet mill for emax restorations and I keep having problems with the 2.5mm diamond milling bur in the number four spot [ZGB2-125DS is the part designation]. It will either:
-Slip out of the collet and snap at the shaft with a piece remaining inside the collet, or
-Remain stuck inside the collet when the machine attempts to deposit the bur and move on in the program
We use all HQ burs [ones with the green collars on them] and I calculate the tool path as High Quality for every job with the Glass Ceramic material selected.
Have any of yall run into this issue with this mill specifically?
If so, how did you fix it?
Gotta say, I'm at the end of my rope with this thing lol
<== The bur in question

 

[TKTECH97]

SOME ADDITIONAL INFO:
I calibrate the machine if this error happens and then do a milling bur change test as well before I continue with the restoration.
I also perform the collet maintenance daily as instructed but it doesn't seem to help this issue

 

[tuyere]

So it changes the other tools correctly, right? It's just the roughing end mill that hangs? Normally I'd say this sounds like a collet problem or a spindle drawbar problem, but if it's only having problems with a specific tool position, that isn't so likely.
Regardless, do you have a replacement collet available? That would be my first try, just swap them out and see if it helps. Also do it with a fresh tool, to control for those variables- just run an ATC tool change a couple times, doesn't need to be a real job.
Inspect the ATC tool pockets and remove any concreted Emax swarf that's present, that's always a pain with Emax stuff, and the dwx-42 design accumulates it in the upright tool pockets compared to other Emax workhorses, like the PM7 with its sideways magazine.
I don't remember how the -42 tool pockets work, if they're just pockets in a metal block, or if there are soft inserts like with the VHF S5 ATC. If it has a wear component or insert, replace that, or swap the positions around if possible and see if that helps.
I might also put a different, incorrect tool in that 2.5mm tool pocket and do an ATC test a few times, just to rule out it being an issue with the 2.5mm tools specifically (I doubt it'd be something to do with the tool, but you never know).

My last guess is something to do with the machine's reference tool positions; it has an XYZ position for where the spindle should end up during tool changes, and if that value is off for some reason, it will ruin your tool changes. Alternately, there may be a lot of wear on the ballscrews in the travel range the tool-changes occur, or some similar issue, and there's so much backlash/slop in those areas that it's not travelling to the exact position it needs to be in for the tool-change to go smoothly.

 

[TKTECH97]

So it changes the other tools correctly, right? It's just the roughing end mill that hangs? Normally I'd say this sounds like a collet problem or a spindle drawbar problem, but if it's only having problems with a specific tool position, that isn't so likely.

Yeah, it changes just fine on the other three tools but this is the only tool that causes the issue.

Regardless, do you have a replacement collet available? That would be my first try, just swap them out and see if it helps. Also do it with a fresh tool, to control for those variables- just run an ATC tool change a couple times, doesn't need to be a real job.

I do not have a replacement on hand unfortunately. We recently (within the past 6 months) had to replace it because the old one became deformed and the tips flared outward (caused by an unrelated error).

Inspect the ATC tool pockets and remove any concreted Emax swarf that's present, that's always a pain with Emax stuff, and the dwx-42 design accumulates it in the upright tool pockets compared to other Emax workhorses, like the PM7 with its sideways magazine.

This is the first thing I'm going to try, the dwx-42 does throw a ton of waste around in the milling chamber so I'm leaning towards this as a cause of the issue.

I don't remember how the -42 tool pockets work, if they're just pockets in a metal block, or if there are soft inserts like with the VHF S5 ATC. If it has a wear component or insert, replace that, or swap the positions around if possible and see if that helps.
I might also put a different, incorrect tool in that 2.5mm tool pocket and do an ATC test a few times, just to rule out it being an issue with the 2.5mm tools specifically (I doubt it'd be something to do with the tool, but you never know).

The -42 just has pockets in a solid metal magazine. Like I said above I'll attempt to clean out the pockets and run an ATC tool change. If that doesn't work, I'll try putting a different tool in the same spot.

All in all thanks for your help! I have some solid leads now lol
If none of this works I'll come back and try the more involved steps of correcting the machines reference tool positions
Thanks again!

 

[Jane Qi]

Sorry for the vague title but I'm running the Roland 42w wet mill for emax restorations and I keep having problems with the 2.5mm diamond milling bur in the number four spot [ZGB2-125DS is the part designation]. It will either:
-Slip out of the collet and snap at the shaft with a piece remaining inside the collet, or
-Remain stuck inside the collet when the machine attempts to deposit the bur and move on in the program
We use all HQ burs [ones with the green collars on them] and I calculate the tool path as High Quality for every job with the Glass Ceramic material selected.
Have any of yall run into this issue with this mill specifically?
If so, how did you fix it?
Gotta say, I'm at the end of my rope with this thing lol
View attachment 44574 <== The bur in question

Hello, @TKTECH97. My name is Jane Qi, customer service specialist at DGSHAPE Global.

Could you please check if there's any damage to the area where the collet of the No. 4 ZGB2-125DS grips? If the gripping part of the collet is scratched, it might affect its ability to grip properly.

Also, could you please check if the milling bur is worn out if it slips out of the collet? If you've been using it beyond its intended lifespan, which is 7 hours specifically for the SD-1 spindle, it's advisable to consider replacing it.

Furthermore, what will happen if you attach this ZGB2-125DS to another stocker? Assuming no issues arise, it suggests a problem with stocker number 4.

Should you need further assistance, please feel free to reach out. Thank you.

Jane Qi

 

[TKTECH97]

Could you please check if there's any damage to the area where the collet of the No. 4 ZGB2-125DS grips?

The collet is fairly new and after checking the interior of the collet, I don't see any signs of scratching. Additionally, the shaft of the milling bur itself does not show any signs of scratching either

Also, could you please check if the milling bur is worn out if it slips out of the collet? If you've been using it beyond its intended lifespan, which is 7 hours specifically for the SD-1 spindle, it's advisable to consider replacing it.

When I do run into this issue the milling bur has only been used for less than or around half the total allowed milling time (about 3 1/2 hours)

 

[Jane Qi]

The collet is fairly new and after checking the interior of the collet, I don't see any signs of scratching. Additionally, the shaft of the milling bur itself does not show any signs of scratching either

When I do run into this issue the milling bur has only been used for less than or around half the total allowed milling time (about 3 1/2 hours)

What will happen if you attach this ZGB2-125DS to another stocker? Assuming no issues arise, it suggests a problem with stocker number 4.

 

[TKTECH97]

What will happen if you attach this ZGB2-125DS to another stocker? Assuming no issues arise, it suggests a problem with stocker number 4.

I did try switching the bur to a different stocking position and running a milling bur change test for the problem bur and a different one. However it changed burs just fine, without issue.

As @tuyere said above, I believe the issue lies with keeping that specific stocking spot clean. Because that specific bur does the rough milling, a ton of milling waste and coolant is being sprayed around the milling chamber and it makes sense that the open spot in the magazine will attract a lot of it.