Grooving & Cut-Off
PROBLEMS |
CAUSES |
SOLUTIONS |
| POOR TOOL LIFE | Excessive cutting speed | Decrease speed |
| Select proper grade for workpiece material | ||
| Use positive rake tools | ||
| Adjust coolant flow & concentration | ||
| SIDE WALLS NOT STRAIGHT | Incorrect set-up | Check set-up, overhang of tool |
| Poor Alignment | Check tool alignment for square | |
| Deflection | Use a correct hand insert | |
| Use sharp tool | ||
| GROOVE BOTTOM NOT STRAIGHT | Tool deflection | Decrease feed |
| Use sharp tool | ||
| Incorrect set-up | Adjust tool center height | |
| Incorrect process | Dwell at bottom of groove (3 rev max) | |
| Use a wider insert | ||
| POOR CHIP CONTROL | Chip too thin | Increase feed |
| Use sharp tool | ||
| Adjust coolant flow & concentration | ||
| BUILT UP EDGE | Poor shearing action | Select a PVD coated grade |
| Increase speed | ||
| Decrease feed | ||
| Use sharp tool | ||
| Use positive rake tools | ||
| Adjust coolant flow & concentration | ||
| INSERT EDGE CHIPPING | Excessive cutting force | Select tougher grade |
| Built-up edge | Decrease feed | |
| Increase speed | ||
| Poor set-up | Check set-up, overhang of tool | |
| CHATTER | Tool deflection, poor set-up | Increase speed |
| Increase feed | ||
| Adjust tool center height | ||
| Check set-up, overhang of tool | ||
| BURR | Poor shearing action | Use sharp tool |
| Use positive rake tools | ||
| Adjust tool center height | ||
| Select a PVD coated grade | ||
| POOR SURFACE FINISH | Poor shearing action, deflection | Increase speed |
| Use sharp tool | ||
| Use positive rake tools | ||
| Adjust coolant flow & concentration | ||
| Check set-up, overhang of tool | ||
| Dwell at bottom of groove (3 rev max) | ||