ProblemCauseSolution
 

Chipping

 

  • Feed Rate too high
  • Up Milling (Conventional)
  • Cutting edge too sharp
  • Chattering
  • Loose Tool
  • Workpiece rigidity
  • Low cutting Speed
  • Loose toolholder
  • Reduce feed rate
  • Change to down milling (climb)
  • Hone cutting edge or allow break-in
  • Reduce RPM
  • Remove, clean and retighten
  • Tighten workpiece holding method
  • Shorten LOC,place shank further up holder
  • Increase RPM
  • Remove from spindle, clean and replace

Breakage

 

  • Feed Rate too high
  • Depth of cut too large
  • Poor tool rigidity
  • Tool wear
  • Poor chip evacuation

 

 

  • Reduce feed rate
  • Reduce depth of cut
  • Shorten LOC,place shank further up holder
  • Replace/regrind sooner
  • Reposition coolant lines,use air blasting

Chattering

 

  • Speed & Feed too high
  • Poor tool holder rigidity
  • Poor Spindle rigidity
  • Workpiece rigidity
  • Relief angle too high
  • Depth of cut too large
  • Poor tool rigidity

 

  • Reduce feed rate
  • Replace with shorter/more rigid holder
  • Use larger spindle or different machine tool
  • Tighten worpice holding method
  • Regrind with smaller relief angle
  • Reduce depth of cut
  • Shorten LOC,place shank further up holder

Short Life

 

  • Cutter / workpiece friction
  • Hard Material
  • Poor material condition
  • Improper cutter angle
  • Poor coolant
  • Use Coated tool
  • Use Coated tool
  • Use Coated tool
  • Use Coated tool,clean material surface
  • Regrind with proper primary relief angle
  • Replace coolant or correct mixture

Chip Packing

 

  • Feed rate too high
  • Low cutting speed
  • Insufficient chip room
  • Insufficient coolant
  • Reduce feed rate or increase speed
  • Increase RPM or reduce feed rate
  • Use tool with less flutes,increase helix
  • Increase volume of coolant

Poor Surface Finish

 

  • Feed rate too high
  • Low cutting speed
  • Tool wear
  • Edge buildup
  • Depth of cut too large
  • Chip welding

 

  • Reduce feed rate or increase speed
  • Increase RPM
  • Use tool with less flutes,increase felix tool
  • Reduce depth of cut
  • Increase volume of coolant

Burning or Workpiece Chipping

 

 

  • Tool wear
  • Improper helix angle
  • Feed rate too high
  • Depth of cut too large
  • Replace or regrind tool
  • Change to recommended helix angle
  • Reduce feed rate
  • Reduce depth of cut

Workpiece Inaccuracy

 

  • Loose/worm tool holder
  • Poor tool holder rigidity
  • Poor spindle rigidity
  • Insufficient number of flutes
  • Tool deflection
 

  • Repair or Replace
  • Replace with shorter/more rigid tool holder
  • Use larger spindle or different machine tool
  • Use tool with higher flute quantity
  • Shorten LOC,place shank up holder