I am asking my question here instead of the woodworking forum because my question is really a general machining question. I haven't had a satisfactory answer from my woodworking forums, nor any searches.
I am pattern routing a plane tote on my router table and I have been experiencing a kickback the moment the cutting edge of the bit touches the work piece. It happens on both a 2 flute, top and bottom bearing flush trim bit and a top bearing flush trim spiral bit. I am trimming away less than 1/8" of red oak end grain. I am also routing from right to left. Oddly, I was able to round over the piece with a 1/2" roundover bit with no kickback. I did get lots of burning and tear out.
After trying several suggestions, I decided to inspect the router. It's Porter Cable 690 and it is very old and it is the first time I am using this particular router. I checked it with my indicator without the bit and I got .005" runout at the shaft and nearly 0 inside the collet. With my thumb, I pressed with firm pressure against the shaft and got over .010" runout depending on how hard I pressed it. During use, there is a lot of vibration, very loud and makes rattling clanking sound as it spins down. I assumed it was because routers are supposed to be noisy.
Can such a deflection on the shaft cause a kickback? If so, why? Moreover, why did the roundover bit not kickback, albeit the finish wasn't very good?
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