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Carbide Tooling Troubleshooting

The guide below is to help you better understand the causes of carbide cutting tool performance and what remedies you might consider to improve performance.

TROUBLESHOOTING GUIDE
PROBLEM
CAUSE
SOLUTION
SHORT LIFE CUTTER/WORKPIECE FRICTION USE COATED TOOL
HARD MATERIAL USE COATED TOOL
POOR MATERIAL CONDITION USE COATED TOOL, CLEAN MATERIAL SURFACE
IMPROPER CUTTER ANGLE REGRIND WITH PROPER PRIMARY RELIEF ANGLE
POOR COOLANT REPLACE COOLANT OR CORRECT MIXTURE
CHIP PACKING    
FEED RATE TOO HIGH REDUCE FEED RATE OR INCREASE SPEED
LOW CUTTING SPEED INCREASE RPM OR REDUCE FEED RATE
INSUFFICIENT CHIP ROOM USE TOOL WITH LESS FLUTES, INCREASE HELIX
INSUFFICIENT COOLANT INCREASE VOLUME OF COOLANT
POOR SURFACE FINISH     
FEED RATE TOO HIGH REDUCE FEED RATE
LOW CUTTING SPEED INCREASE RPM
TOOL WEAR REPLACE OR REGRIND TOOL
EDGE BUILD UP INCREASE RPM, SWITCH TO HIGHER HELIX TOOL
DEPTH OF CUT TOO LARGE REDUCE DEPTH OF CUT
CHIP WELDING INCREASE VOLUME OF COOLANT
BURRING OR WORKPIECE CHIPPING    
TOOL WEAR REPLACE OR REGRIND TOOL
IMPROPER HELIX ANGLE CHANGE TO RECOMMENDED HELIX ANGLE
FEED RATE TOO HIGH REDUCE FEED RATE
DEPTH OF CUT TOO LARGE REDUCE DEPTH OF CUT
WORKPIECE ANACCURACY    
LOOSE/WORN TOOLHOLDER REPAIR OR REPLACE
POOR TOOLHOLDER RIGIDITY REPLACE WITH SHORTER/MORE RIGID TOOLHOLDER
POOR SPINDLE RIGIDITY USE LARGER SPINDLE OR DIFFERENT MACHINE TOOL
INSUFFICIENT NUMBER OF FLUTES USE TOOL WITH HIGHER FLUTE QUANTITY
TOOL DEFLECTION SHORTEN LOC, PLACE SHANK FURTHER UP HOLDER
PROBLEM CAUSE SOLUTION
CHIPPING
FEED RATE TOO HIGH REDUCE FEED RATE
UP MILLING  (CONVENTIONAL) CHANGE TO DOWN MILLING (CLIMB)
CUTTING EDGE TOO SHARP HONE CUTTING EDGE OR ALLOW BREAK-IN
CHATTERING REDUCE RPM
LOOSE TOOL REMOVE, CLEAN, AND RETIGHTEN
WORKPIECE RIGIDITY TIGHTEN WORKPIECE HOLDING METHOD
TOOL RIGIDITY SHORTEN LOC, PLACE SHANK FURTHER UP HOLDER
LOW CUTTING SPEED INCREASE RPM
LOOSE TOOLHOLDER REMOVE FROM SPINDLE, CLEAN AND REPLACE
WEAR
   
HIGH CUTTING SPEED REDUCE RPM
LOW FEED RATE INCREASE FEED RATE
UP MILLING (CONVENTIONAL) CHANGE TO DOWN MILLING (CLIMB)
HARD MATERIAL USE COATED TOOL
POOR CHIP EVACUATION REPOSITION COOLANT LINES, USE AIR BLASTING
IMPROPER CUTTER HELIX CHANGE TO RECOMMENDED HELIX ANGLE
POOR COOLANT REPLACE COOLANT OR CORRECT MIXTURE
BREAKAGE
   
FEED RATE TOO HIGH REDUCE FEED RATE
DEPTH OF CUT TOO LARGE REDUCE DEPTH OF CUT
POOR TOOL RIGIDITY SHORTEN LOC, PLACE SHANK FURTHER UP HOLDER
TOOL WEAR REPLACE/REGRIND SOONER
POOR CHIP EVACUATION REPOSITION COOLANT LINES, USE AIR BLASTING
CHATTERING    
SPEED AND FEED TOO HIGH REDUCE FEED RATE
POOR TOOLHOLDER RIGIDITY REPLACE WITH SHORTER/MORE RIGID HOLDER
POOR SPINDLE RIGIDITY USE LARGER SPINDLE OR DIFFERENT MACHINE TOOL
WORKPIECE RIGIDITY TIGHTEN WORKPIECE HOLDING METHOD
RELIEF ANGLE TOO HIGH REGRIND WITH SMALLER RELIEF ANGLE
DEPTH OF CUT TOO LARGE REDUCE DEPTH OF CUT
POOR TOOL RIGIDITY SHORTEN LOC, PLACE SHANK FURTHER UP HOLDER

 

 

 

 

 

Click on thumbnail form below to access an PDF version of our Tool Performance Report Form

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