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
