PROBLEM | PROBABLE CAUSES | POSSIBLE SOLUTIONS |
Breakage | Excessive feed | Reduce feed |
Lack of rigidity | Make tool or work rigid |
Improperly applied coolant | Be sure coolant is on cutting point of tool |
Chipbreaker too narrow | Use a wider chipbreaker |
Dull insert | Re-index or replace insert |
Carbide grade too soft | Use higher strength carbide |
Built-up edge | Improperly applied coolant | Increase coolant flow |
Speed and feed too slow | Increase speed or increase feed |
Rake angle too slight | Use positive rake angle |
Chatter | Incorrect feed | Increase feed |
Too large a nose radius | Reduce nose radius |
Lack of rigidity | Make tool or work rigid |
Improper angles | Decrease rake angle or increase relief and clearance angle or check mounting horsepower, spindles |
PROBLEM | PROBABLE CAUSES | POSSIBLE SOLUTIONS |
Chip Clogging | Chips too long | Use narrower chipbreaker or increase chip wells |
Excessive feed | Reduce feed |
Chipping | Chipbreaker too narrow | Use a wider chipbreaker |
Improper angles | Use negative rake angles or small relief angles or use larger nose radius or use cutting edge angle or use pre-honed inserts |
Excessive feed | Reduce feed |
Lack of rigidity | Make tool or work rigid |
Carbide grade | Use higher strength carbide |
Scale or voids in workpiece | Increase speed |
Cratering | Excessive speed, feed, or both, eroding top of tool | Reduce speed or reduce feed or use a carbide grade higher in crater resistance |
Rake angle too slight | Use positive rake angles |
PROBLEM | PROBABLE CAUSES | POSSIBLE SOLUTIONS |
Deformation | High temperature at cutting edge | Reduce speed or reduce feed or use a harder grade of carbide |
Large Volume metal removal | Reduce tool angles or increase nose radius or use positive rake tools |
Excessive Wear | Speed too high or feed too light | Reduce speed or increase feed |
Carbide too soft | Use more wear resistance carbide |
Improper angle | Increase side cutting angle or use larger relief angle |
Notching | High abrasive surface scale or work hardened previously machined surface | Increase a side cutting edge angle or reduce feed or use a larger radius or reduce speed |
Poor Finish | Feed rate too high | Decrease feed, increase nose radius |
Surface speed low | Increase speed |
Lack of rigidity | Make tool or work rigid |
Dull insert | Re-index or replace insert |
PROBLEM | PROBABLE CAUSES | POSSIBLE SOLUTIONS |