| Problème |
Causes |
Solutions |
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| CHIP
PACKING |
-Too
great a cutting amount |
Adjust feed or speed |
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| -Not
enough chip room |
Use end mill fewer
flutes |
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|
|
|
| -Not enough
coolant |
Apply more coolant.
Use air pressure |
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|
-Feed
too fast |
Slow
down to correct feed |
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|
|
| ROUGH
SURFACE FINISH |
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|
|
| -Slow
speed |
Use
higher speed |
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|
| -Too
much wear |
Regrind
earlier stage |
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|
|
|
| -Chip
biting |
Cut
less amount per pass |
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| |
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|
|
| -No
end tooth concavity |
Add
margin (touch primary with oilstone) |
|
|
|
|
|
| BURR |
-Too
much wear on primary relief |
Regrind sooner |
|
|
|
|
| -Incorrect
condition |
Correct milling condition |
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|
|
|
| -Improper
cutting angle |
Change to correct
cutting angle |
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|
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|
|
| NODIMENSIONAL
ACCURACY |
-Too
tough condition |
Change
to easier condition |
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|
|
|
| -Lack
of accuracy (machine & holder) |
Repair
machine or holder |
|
|
|
|
| -Not
enough rigidity (machine & holder) |
Change
machine or holder or condition |
|
|
|
|
| -Not
sufficient number of flutes |
Use
end mill with greater number of flutes |
|
|
|
|
|
| NO PERPENDICULAR
SIDE |
-Feed too
fast |
Slow down to correct
feed |
|
|
|
|
| -Too great
a cutting amount |
Reduce cutting amount |
|
|
|
|
| -Too long
a flute length or long overall length |
Use proper length tool.
Hold shank deeper |
|
|
|
|
| -Not sufficient
number of flutes |
Use end mill with greater
number of flutes |
|
|
|
|
|
| CHIPPING |
-Feed
too fast |
Slow
down to proper feed |
|
|
|
|
| -Feed
too fast on first cut |
Slow
down on first bite |
|
|
|
|
| -Not
enough rigidity of machine tool & holder |
Change
rigid machine tool or holder |
|
|
|
|
| -Loose
holder |
Tighten
tool holder |
|
|
|
|
| -Loose
holder (workpiece) |
Tighten
workpiece fixture |
|
|
|
|
| -Lack
of rigidity (tool) |
Use
shortest end mill available. Hold shank deeper. Try down
cut |
|
|
|
|
| -Teeth
too sharp |
Change
to lower cutting angle, primary relief |
|
|
|
|
|
|
WEAR |
-Speed
too fast |
Slow down, use more
coolant |
|
|
|
|
|
-Hard
material |
Use higher grade, tool
material, add surface treatment |
|
|
|
|
| -Biting
chips |
Change feed speed to
change chip size or clear chips with coolant or air
pressure |
|
|
|
|
| -Improper
feed speed (too slow) |
Increase feed speed.
Try down cut |
|
|
|
|
| -Improper
cutting angle |
Change to correct cutting
angle |
|
|
|
|
| -Too low
a primary relief angle |
Change to larger relief
angle |
|
|
|
|
|
| BREAKAGE
|
-Feed
too fast |
Slow
down feed |
|
|
|
|
| -Too
large cutting amount |
Adjust
to smaller cutting amount per teeth |
|
|
|
|
| -Too
long flute length or long overall length |
Hold
shank deeper, use shorter end mill |
|
|
|
|
| -Too
much wear |
Regrind
at earlier stage |
|
|
|
|
|
| CHATTERING |
Feed and
speed too fast |
Correct feed and speed |
|
|
|
|
| Not enough
rigidity (machine & holder) |
Use better machine
tool or holder or change condition |
|
|
|
|
| Too much
relief angle |
Change to smaller relief
angle. Add margin (touch primary with oil stone) |
|
|
|
|
| Loose holder
(workpiece) |
Hold workpiece tighter |
|
|
|
|
| Cutting
too deep |
Correct to smaller
cutting depth |
|
|
|
|
| Too long
flute length or long overall length |
Hold shank deeper,
use shorter end mill or try down cut |
|
|
|
|
|
SHORT
TOOL LIFE
(DULL TEETH)
HAUT DE PAGE |
Too
much cutting friction |
Regrind
at earlier stage |
|
|
|
|
| Tough
work material |
Select
premium tool |
|
|
|
|
| Improper
cutting angle |
Change
cutting angle & primary |
