- Click on the problems to see probable
causes and solutions!
Problems
Thermal cracks
Causes
- Large cutting edge diameter used.
- Coolant was used.
Solutions
- Use a sharper geometry to prevent heat.
- Use a high thermal-shock resistant tool grade.
- Use copious amounts of coolant.
Notch ware
Causes
- Hard workpiece surface.
- Oxidation occurs at the boundary.
- Rubbing of burrs.
Solutions
- Use a larger rake angle (sharper cutting edge).
- Prevent vibration & heat generation.
Chipping
Causes
- Tool grade too hard.
- Honing too small.
- S point or ST line contact.
- Thermal cracks or notching has occurred.
- Feed rate too high.
- Chips contacting with the cutting edge.
- Vibrations occurred.
- Backlash in the table feed.
Solutions
- Increase the honing size.
- Increase the cutting speed to effectively. discharge the chips.
- Prevent vibrations from occurring.
- If there is backlash use up cut machining.
- Adjust the feed & depth of cut.
Fracturing
Causes
- Tool grade too hard.
- Honing too small.
- S point or ST line contact.
- Thermal cracks or notching has occurred.
- Feed rate too high.
- Chips contacting with the cutting edge.
- Vibrations occurred.
- Backlash in the table feed.
Solutions
- Increase the honing size.
- Increase the cutting speed to effectively discharge the chips.
- Prevent vibrations from occurring.
- If there is backlash use up cut machining.
- Adjust the feed & depth of cut.
Flaking
Causes
- Cutting edge under compressive stress.
- Welded sections peel away from the cutting edge.
Solutions
- Use a sharper cutting edge.
- Use a face mill with larger chip pockets.
- Adjust the cutting conditions.
Breakage
Causes
- Insert not set correctly.
- Too high cutting conditions leading to vibrations.
Solutions
- Clean the insert pocket.
- Ensure that the insert is set correctly.
- Use the correct torque level.
- Reduce the cutting conditions.
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