What causes a router bit to fail and/or break?

The most common reasons for carbide-tipped or solid carbide router bits to fail or break are:

  • Wrong router bit for the application
  • Extreme chipload per flute
  • Dull router bit
  • Poor quality collets
  • Collet toque set improperly
  • Part moving or chattering while being cut
  • Motor issue (i.e. bearings going bad)
  • To low or high RPM or feed rate