Troubleshooting Carbide Endmills | Carbide Drills | Carbide Reamers Problem Cause Solution Chipping Feed rate too high Up milling (conventional) Cutting edge too sharp Chattering Loose tool Workpiece rigidity Tool rigidity Low cutting speed Loose toolholder Reduce feed rate Change to down milling (climb) Hone cutting edge or allow break-in Reduce RPM Remove, clean, and retighten Tighten workpiece holding method Shorten LOC, place shank further up holder Increase RPM Remove from spindle, clean and replace Wear High cutting speed Low feed rate Up milling (conventional) Hard material Poor chip evacuation Improper cutter helix Poor coolant Reduce RPM Increase feed rate Change to down milling (climb) Use coated tool Reposition coolant lines, use air blasting Change to recommended helix angle Replace coolant or correct mixture Breakage Feed rate too high Depth of cut too large Poor tool rigidity Tool wear Poor chip evacuation Reduce feed rate Reduce depth of cut Shorten LOC, place shank further up holder Replace/regrind sooner Reposition coolant lines, use air blasting Chattering Speed and feed too high Poor toolholder rigidity Poor spindle rigidity Workpiece rigidity Relief angle too high Depth of cut too large Poor tool rigidity Reduce feed rate Replace with shorter/more rigid holder Use larger spindle or different machine tool Tighten workpiece holding method Regrind with smaller relief angle Reduce depth of cut Shorten LOC, place shank further up holder Short Life Cutter/workpiece friction Hard material Poor material condition Improper cutter angle Poor coolant Use coated tool Use coated tool Use coated tool, clean material surface Regrind with proper primary relief angle Replace coolant or correct mixture Chip Packing Feed rate too high Low cutting speed Insufficient chip room Insufficient coolant Reduce feed rate or increase speed Increase RPM or reduce feed rate Use tool with less flutes, increase helix Increase volume of coolant Poor Surface Finish Feed rate too high Low cutting speed Tool wear Edge build up Depth of cut too large Chip welding Reduce feed rate Increase RPM Replace or regrind tool Increase RPM, switch to higher helix tool Reduce depth of cut Increase volume of coolant Burring or Workpiece Chipping Tool wear Improper helix angle Feed rate too high Depth of cut too large Replace or regrind tool Change to recommended helix angle Reduce feed rate Reduce depth of cut Workpiece Inaccuracy Loose/worn toolholder Poor toolholder rigidity Poor spindle rigidity Insufficient number of flutes Tool deflection Repair or replace Replace with shorter/more rigid toolholder Use larger spindle or different machine tool Use tool with higher flute quantity Shorten LOC, place shank further up holder