Problem
|
Cause
|
Solution
|
| Tool Breakage |
Heat buildup due to incorrect tool selection |
Use correct tool for material being cut |
| |
Heat due to inadequate chip removal |
Use up spiral tool to help in chip removal |
| |
Too high a plunge rate |
Reduce plunge rate |
| |
Blunt tool |
Replace tool |
| |
Tool runout |
Tighten tool in collet or if necessary change collet |
| |
Worn collet |
Replace collet |
| |
Too high a feed rate |
Reduce feed rate |
| |
Too high a chip load |
Reduce feed rate or increase RPM or change tool to one with more flutes |
| |
Vibration |
Improve workpiece hold down to machine bed |
| |
Tool not fitted correctly in collet |
Re-fit tool in collet ensuring at least 80% of collet length is used |
| |
Tool deflection |
Reduce feed rate but if possible use larger diameter tool |
| Poor cut finish due to chip rewelding to cut edge |
No coolant |
Use mist coolant or cold air gun |
| |
Blunt tool |
Replace tool |
| |
Too slow a feed rate |
Increase feed rate |
| |
Incorrect tool selection for material |
Choose correct tool for material being machined |
| |
Heat due to inadequate chip removal |
Use up spiral tool |
