PROBLEMS |
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 | ||
| 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 | ||
| UNACCEPTABLE CHIP CONTROL | Chip too thin | Increase feed rate |
| Use more positive chipbreaker | ||
| Select smaller nose radius insert | ||
| Decrease lead angle | ||
| POOR
INSERT LIFE (Use 10x magnifier to identify the following typical failure modes) 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 | |
Crater Wear  |
Excessive heat at chip/tool interface | Reduce cutting speed |
| Flood cutting zone with coolant | ||
| Select more positive rake chipbreaker | ||
| Excessive cutting force | Reduce feed rate | |
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 | |
Chipping |
Chatter, vibration | See chatter |
| 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 | ||
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 | ||
Thermal Cracks |
Extreme variation in cutting temperature | Reduce feed rate |
| Increase cutting speed | ||
| Interrupted cut | Use stronger chipbreaker | |
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 | ||
