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 |
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