PREMIUM QUALITY AMERICAN-MADE CUTTING TOOLS Technical Information
Trouble Shooting Guide END MILLS - CARBIDE
PROBLEM CAUSE
SOLUTION
Premature Wear
• Cutting speed is too fast • Hard/Abrasive work-piece material • Speed and/or feed is too light • Helix angle is incorrect for application • Re-cutting chips
• Decrease spindle speed • Use coatings (TiCN, AlTiN) • Increase speed and/or feed • Select tool with appropriate helix angle
• Adjust speed & feed, axial and/or radial D.O.C., Increase coolant pressure and/or air to clear chips.
Edge Chipping
• Feed rate too aggressive • Feed rate too aggressive on initial cut • D.O.C. too aggressive • Tool rigidity
• Reduce feed rate • Reduce feed rate on initial pass • Decrease axial and/or radial D.O.C. • Change tool holder, hold shank deeper and/or use shorter tool • Re-fixture work-piece and/or improve setup • Check spindle for run-out • Reduce feed rate • Reduce axial and/or radial D.O.C. • Hold shank deeper, use shorter endmill • Adjust speed and/or feed, select endmill with fewer flutes, increase coolant pressure and/or air • Re-grind tool sooner • Reduce speed and/or feed • Use endmill with less flutes • Increase coolant and/or air pressure, reposition nozzle to point of cut • Reduce speed and/or feed • Change tool holder, hold shank deeper and/or use shorter tool • Re-fixture work-piece and/or improve setup • Check spindle for run-out • Reduce axial and/or radial D.O.C. • Adjust speed & feed • Change to correct helix angle, use climb milling • Re-grind tool sooner
• Work-piece rigidity • Machine tool rigidity
Breakage
• Feed rate too aggressive • D.O.C. too aggressive • Excessive tool overhang • Chip packing • Excessive wear
Chip Packing
• Speed and/or feed too aggressive • Flute gullet too small for chips • Insufficient coolant volume and/or pressure
Chattering
• Speed and/or feed too aggressive • Tool rigidity
• Work-piece rigidity • Machine tool rigidity • D.O.C. too aggressive • Wrong tool geometry
Burs
• Incorrect speed & feed • Helix angle is incorrect for application • Primary cutting edge(s) are dull
Poor Finish
• Feed rate too aggressive • Speed is too slow • D.O.C. too aggressive • Excessive wear • D.O.C. too aggressive • Tool Rigidity • Machine tool rigidity
• Reduce feed rate • Increase spindle speed (RPM) • Reduce axial and/or radial D.O.C. • Re-grind tool sooner
Poor Dimensional Accuracy
• Reduce axial and/or radial D.O.C. • Use tool with more flutes • Check, inspect & repair machine tool, tool holder and fixtures
MADE IN THE USA
223
Powered by FlippingBook