Carbide End Mills
Troubleshooting

Carbide End Mills | 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
    •


    Tungsten ToolWorks is a manufacturer of customized (special) solid carbide cutting tools, sold worldwide under the Tungsten ToolWorks brand name. Products include solid carbide end mills, drills, reamers, burrs, micro tools, sub-miniature tools, micro tools, engraving tools, boring tools, keyseat cutters, burrs, slitting saws, carbide cylinders, countersinks, routers, radius mills, CBN tools, compression tools, and more. Technologies include SmoothCoat PVD hard coatings, SmoothGrind polished cutting edges, SmoothEdge prep and hone, and SmoothContricity shrink fit ready shanks. Coatings include D2 CVD diamond, D1 PVD amorphous diamond, TA TiAlN, AT AlTiN, TN TiN, TC TiCN, and A1 TiB2. Industries using our products include aerospace, semiconductor, die & mold, micro (nano) machining, woodworking, medical, consumer electronics, automotive and more. Workpiece materials to be drilled, milled, reamed, routed, engraved and more include titanium (6Al-4V, 5553), stainless (303, 304, 316, 410, 420, 440C, 15-5, 17-4, 13-8, 316L), tool steels (A2, D2, H13), general steels (1018, 1020, 4140, 4340, P20), Inconel (625, 718), cast iron, non-ferrous materials including aluminum, copper, brass, bronze, wood & plastics, CFRP (carbon fiber reinforced plastic), graphite, composites, fiberglass, and more. Tungsten ToolWorks is a Tool Alliance company.