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Troubleshooting Cutting Problems

For every problem there is a possible cause and a solution.

Here are some typical problems that you may encounter and possible solution for each problem.

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