- Click on the problems to see probable
causes and solutions!
Problems
Poor surface finish
Causes
- Incorrect cutting conditions.
- Low run-out accuracy.
- Vibrations occurred.
Solutions
- Increase the cutting speed.
- Improve the run-out accuracy.
- Use a sharper cutting edge.
- Decrease the No. of teeth.
- Use a wiper insert.
- Improve the tool rigidity.
Burrs are formed
Causes
- Chip thickness is too thick.
- Tool diameter is too large.
- Cutting edge is not sharp enough.
- Too large a corner angle.
Solutions
- Increase the cutting speed..
- Reduce the feed/depth of cut.
- Select a tool diameter suitable for the workpiece width.
- Use a sharper cutting edge.
- Use a smaller corner angle.
Workpiece chipping
Causes
- Cutting conditions not appropriate.
- Cutting edge is not sharp enough.
- Too small a corner angle.
- Vibrations occurred.
Solutions
- Reduce the feed/depth of cut.
- Use a sharper cutting edge.
- Use a larger corner angle.
- Improve the tool rigidity.
Poor flatness & parallelism
Causes
- Workpiece deflects.
- Tool deflects.
- Back forces too high.
Solutions
- Reduce the feed/depth of cut.
- Use a sharper cutting edge.
- Use a smaller corner angle.
- Reduce the No. of teeth.
- Improve the tool rigidity.
Large vibration
Causes
- Improper cutting conditions.
- Tool diameter is too large.
- Cutting resistance is too high.
- Clamping rigidity is too low.
Solutions
- Reduce the cutting conditions.
- Select a tool diameter suitable for the
- Use a sharper cutting edge.
- Reduce the No. of teeth.
- Improve the work clamp rigidity.
Chip jamming
Causes
- Welding occurs.
- Chip thickness is too thin.
- Tool diameter is too small.
- Poor chip discharge.
Solutions
- Increase cutting speed.
- Increase feed.
- Increase the tool diameter.
- Use coolant.
- Choose a tool with larger chip pockets (reduce the number of teeth).
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