PROBLEM |
CAUSES |
SOLUTIONS |
POOR SURFACE FINISH |
Feed rate too great for nose radius |
Reduce feed rate |
Use larger nose radius insert |
Low cutting speed |
Increase cutting speed |
Poor shearing action |
Select more positive chipbreaker |
Flood cutting zone with coolant |
PROBLEM |
CAUSES |
SOLUTIONS |
WORKPIECE CHATTER / VIBRATION |
Poor Set-Up |
Use sharp inserts |
Improper insert selection |
Select more positive chipbreakers |
Increase feed rate |
Increase lead angle |
Use smaller nose radius tools |
PROBLEM |
CAUSES |
SOLUTIONS |
UNACCEPTABLE CHIP CONTROL |
Chip too thin |
Increase feed rate |
Use more positive chipbreaker |
Select smaller nose radius insert |
Decrease lead angle |
PROBLEM |
CAUSES |
SOLUTIONS |
POOR INSERT LIFE - Flank Wear |
Excessive heat |
Reduce cutting speed. |
Flood cutting zone with coolant |
Select more positive rake chipbreaker |
Work material microstructure contains carbides |
Use harder carbide grade |
PROBLEM |
CAUSES |
SOLUTIONS |
POOR INSERT LIFE - Crater Wear |
Excessive heat at chip/tool interface |
Reduce cutting speed |
Flood cutting zone with coolant |
Select more positive rake chipbreaker |
PROBLEM |
CAUSES |
SOLUTIONS |
POOR INSERT LIFE - Built-up Edge |
Poor shearing action |
Use sharp edge inserts |
Use grades with high lubricity surfaces (PVD coated grades, cermet grades, polished carbide grades) |
Use coolant to reduce chip adherence when cutting gummy materials |
High cutting forces |
Use more positive chipbreaker |
Low cutting speed |
Increase speed |
PROBLEM |
CAUSES |
SOLUTIONS |
POOR INSERT LIFE - Chipping |
Chatter, vibration |
Use sharp inserts |
Select more positive chipbreakers |
Increase feed rate |
Increase lead angle |
Use smaller nose radius tools |
Built-up edge |
Increase speed, use PVD coated grade, use coolant |
Decrease feed per tooth |
Excessive cutting force |
Use hone or T-land |
Use tougher grade |
Select stronger chipbreaker |
PROBLEM |
CAUSES |
SOLUTIONS |
POOR INSERT LIFE - Depth of Cut Notching |
Scale part |
Increase lead angle |
Increase cutting speed |
High work hardening materials |
Select tougher grade |
Select stronger chipbreaker |
Vary depth of cut if possible |
PROBLEM |
CAUSES |
SOLUTIONS |
POOR INSERT LIFE - Thermal Cracks |
Extreme variation in cutting temperature |
Reduce feed rate |
Increase cutting speed |
Interrupted cut |
Use stronger chipbreaker |
PROBLEM |
CAUSES |
SOLUTIONS |
POOR INSERT LIFE - Fracture |
Extreme cutting conditions, excessive cutting force, chatter |
Reduce feed rate |
Select tougher grade |
Select stronger chipbreaker |
Make sure set-up is as rigid as possible |