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Application Particulières
 
Usinage - Fraisage - Indexable End Mill Troubleshooting
Flank Wear   Crater Wear   Built-up Edge   Chipping   DOC Notching   Thermal Cracks  
FLANK WEAR CRATER WEAR BUILT-UP EDGE Chipping Depth-of-cut notching     Thermal cracking   
 PROBLEM  CAUSES SOLUTIONS
CHATTER (lines or grooves at regular intervals) -Lack of rigidity Check spindle & fixture rigidity
-Excessive cutting force Reduce feed rate, depth of cut or width of cut if excessive
-Thin-walled part Dampen part
 PROBLEM   CAUSES SOLUTIONS
POOR SURFACE FINISH - Roughness -Insert worn Use more wear resistant coated grade
-Built-up edge Increase speed, use PVD coated inserts, use coolant
-High tooth Correct improper preset. Set wiper
-Wiper insert set too highy .0005" to .002" above high insert
 PROBLEM   CAUSES SOLUTIONS
POOR SURFACE FINISH - Flatness -Deflection Check for deflection of part, cutter or spindle
-Improper spindle tilt (milling machines) Check spindle tilt - .0015" per foot is recommended
-Excessive cutting force Use a more positive rake cutter
-Width of cut too large for cutter Use a larger diameter cutter
HAUT
 PROBLEM   CAUSES SOLUTIONS
POOR SURFACE FINISH - Waviness -Advance per revolution greater than width of flat of insert Deflection
Reduce feed rate
 PROBLEM   CAUSES SOLUTIONS
PART BURRING -Insert worn Use more wear resistant coated grade
-Excessive insert edge prep Reduce or avoid hone or T-land
-Improper angle of entry or exit of cutter Change position of center of cutter over part
-Improper lead angle Use larger lead angle; avoid 0 lead angle cutters
-Chip load too great or too small Increase or decrease chip load

PROBLEM

CAUSES SOLUTIONS

WORKPIECE BREAKOUT

-Improper geometry Use larger lead angle; avoid 0 lead angle cutters
Use inserts with double facet corners

-Improper angle of entry or exit of cutter

Change position of center of cutter over part
PROBLEM CAUSES SOLUTIONS
POOR INSERT LIFE - Flank Wear -Excessive heat Reduce speed. Increase chip load to carry away heat
Use coolant
-Incorrect grade Use a more wear resistant coated grade
PROBLEM CAUSES SOLUTIONS
POOR INSERT LIFE - Crater Wear -Excessive heat Use a more heat resistant coated grade (Al2O3 layer)
Reduce speed
Flush with coolant
HAUT
-Excessive cutting force Reduce feed rate
PROBLEM CAUSES SOLUTIONS
POOR INSERT LIFE - Built-up Edge Insufficient cutting temperature causes chip adherence to insert Increase speed
Use coolant to aid lubricity
Use sharp edge inserts
Use grades with high lubricity surfaces (PVD coated grades, Cermet grades, polished carbide grades)
PROBLEM CAUSES SOLUTIONS
POOR INSERT LIFE - Chipping Chatter Check spindle & fixture rigidity
Reduce feed rate, depth of cut or width of cut if excessive
Use sharp edge inserts; avoid hone or T-land
Insufficient edge prep Use hone or T-land
Incorrect grade Use tougher grade
Built-up edge Increase speed, use PVD coated grade, use coolant
Excessive cutting force Decrease feed per tooth
Re-cutting chips Use cutter with chip gullets large enough for chip clearance.
Use air blast or coolant to remove chips.
PROBLEM CAUSES SOLUTIONS
POOR INSERT LIFE - Depth of Cut Notching Scale part, high work hardening materials Use larger lead angle; avoid 0 lead angle cutters
Use more wear resistant grade
Reduce feed per tooth
Reduce speed
Use T-land
Vary depth of cut
PROBLEM CAUSES SOLUTIONS
POOR INSERT LIFE - Thermal Cracks Heat stresses due to temperature variations Reduce speed
Use cutter with more positive geometry
Use grade designed for use with coolant
Discontinue coolant use
 
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