TROUBLE SHOOTING GUIDE

CUTTING TOOLS – CUTTING SPEED – GUIDE

This cutting tools and cutting speed trouble shooting guide will help you with common problems faced during machining.

Reference

Cause

Remedy

Excessive flankwearcutting-tools-trouble-shooting-1

 

Cutting speed too high,
Infeed per pass too small-or too many passes,
Infeed method incorrect
Incorrect carbide grade
– Reduce the cutting speed
– Also, increase the cutting depth per pass to minimum 0.05 mm on the last pass
– Change to modified flank infeed method
– Select a more wear resistant grade in the
grade optimizing chart

Plastic deformation

cutting-tools-trouble-shooting-2

Excessive temperature in the cutting zone
Incorrect carbide grade
Poor coolant supply
Excessive amount of material to machine
– Reduce the cutting speed
– Increase the number of passes-reduce
the largest infeed depth
– Select a grade with better resistance against
plastic deformation in the grade optimizing chart
– Increase the coolant supply
– Check the component dimensions before the threading operation

Edge failure

cutting-tools-trouble-shooting-3

Too high load on the cutting edge
Incorrect carbide grade
Poor chip control
Bad stability
– Increase the number of passes (less infeed per pass)
– Also, choose a tougher grade in the grade optimizing chart
– Change to modified flank infeed
– Check the coolant supply (to assist chip removal)
– Check and eventually stablize the setup

Chipping (both edge and flank)

cutting-tools-trouble-shooting-4

Vibrations
Incorrect carbide grade
Poor coolant supply
– Check the stability of both the tool and the component
– Choose a tougher grade in the grade optimizing chart
– Increase and improve the coolant supply

Unequal flankwear

cutting-tools-trouble-shooting-5

Incorrect helix angle of the tool
compared to the lead angle of the thread
Incorrect infeed method
– Modify your choice of anvil in the anvil selection chart
– Use modified flank infeed method

Built up edge

cutting-tools-trouble-shooting-6

Too low temperature in the cutting zone
Incorrect carbide grade
– Increase the cutting speed
– Do not use coolant
– Select a coated insert or an insert that is able
to withstand high cutting speeds

Vibration

 

Incorrect cutting data
Poor stability
Centre height incorrect
– Increase the cutting speed
– Reduce the overhang and select the most
rigid holder(Use the most rigid set up possible)
– Also, check the centre height and the dimension of
the workpiece (the smaller the diameter, the more
important is the centre height)

Poor surface finish

 

Incorrect cutting data
Incorrect helix angle of the tool compared to the desired lead angle of the thread
Infeed method incorrect
– Increase the cutting speed
– Also, modify your choice of anvil in the anvil selection chart
– Also, choose modified flank or radial infeed method

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