MILLING
Damage at Cutting Edge
Extreme Flank Wear
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TURNING
DETERMINING TOOL LIFE
Not in Tolerance
Improper installation of insert
Dull Cutting
Indexing and machine adjustment
Deterioration of Surface
Consider surface finish when finishing steel, cast iron, and machining aluminum
Generation of Heat
Workpiece overheating can cause loss of surface finish and holding of required tolerances
Burrs, Chipping, etc.,
Steel, aluminum alloy »Burrs
Cast iron »Chipping
Mild steel »Burrs
Damage at Cutting Edge
Heavy Flank Wear and Cratering
Chipping
Breakage
Thermal Cracking
Deformation of Nose Radius
Poor Chip Dispersal
A continuous chip can damage insert and workpiece.Dangerous to operators. Could stop unmanned and automated produc- tion lines.
Tightly rolled chips can effect surface finish and cause vibration.
Uncontrolled chip flow will effect surface finish and quality.
MILLING
COMMON PROBLEMS WHEN MILLING
Damage at Cutting Edge
Extreme Flank Wear
Extreme Cratering
Chipping and Fracturing of Cutting Edge
Cracking and Fracturing Due to Thermal Shock
Edge Build-up
Tolerance
Poor Surface Finish
Burrs, Chipping, etc.
Not Parallel or Irregular Surface
Others
Vibration
Poor Chip Dispersal, Chip Jamming and Chip Packing
END MILLING
Damage on the Body
Endmill Breakage
Damage at Cutting Edge
Rapid Cutting Edge Wear
Chipping
Chip Welding
Tolerance
Poor Finished Surface
Waviness
Out of Vertical
Burr, Workpiece Chipping
Chattering
Chip Control
Poor Chip Disposal
Others
DRILLING
Drill Body Damage
Fracturing of Drill
Chipping along Flutes
Damage to Cutting Edge
Chisel Breakage
Breakage of Peripheral Cutting Edge
Chipping
Flaking along Margin
Thermal Cracking
Short Tool Life
Chips
Chip Packing
Long Stringy Chips
Chip Form Varies
Tolerance of Hole
Poor Surface Finish
Oversize or Out-of-round
Deflection
Common Problems when Drilling
Point Deflection
Galling
Vibration
Abnormal Noise