Are you a programmer, a machinist, a technical/applications engineer, or want to know more about end mills? We compiled some steps to follow when troubleshooting premature end mill failures to help you figure out quickly what's going on and get you back up and running sooner.
Follow these 6 steps to troubleshoot issues with your end mill.
Identify the problem: observe your cutting process and try to identify the problem. Common issues include chatter, broken or chipped tools, poor surface finish, or excessive tool wear.
Check tool geometry: make sure your end mill is sharp and its geometry is correct for the material your cutting in.
Check tool holders and work-holding devices: ensure that your tool holder is tight and secure and that the workpiece is held firmly in place.
Check machine conditions: make sure your machine is running smoothly, with no vibration or excessive noise. Check for loose bolts or other mechanical issues that may affect cutting performance.
Consider your material and cutting parameters: the type of material you are cutting can have a significant impact on cutting performance. Ensure you are using the right end mill, and check the speed and feed rates, and depth of cut to make sure they are appropriate for your material and end mill.
Inspect your tool regularly: regularly inspect the tool for signs of wear, damage, or other issues. Replace the tool if necessary.
We also are providing some common problems encountered in machining operations. While it can be helpful in identifying the source of many problems, keep in mind our applications and engineering teams will always be available to help you optimize your cutting tools.
End Mill Troubleshooting Guide
Feed Rate Excessive
Increase SFM or decrease feed
Depth of Cut Excessive
Reduce the Depth of Cut
Excessive Tool Overhang
Reduce Tool Stick Out
Excessive Tool Wear
Regrind or Cange Tool Sooner
Speed is Too Fast
Hard Work Material
Adjust to Suggested Speed/Feed
Primary Relief Angle Too Low
Change to Larger Relief Angle
Change Feed/Add Air or Coolant
Poor Surface Finish
Feed Rate Too Fast
Correct Feed/Speed Rates
Cutting Speed Too Slow
Change Feed & Speed/Add Air or Coolant
Regrind or Change Tool Sooner
Check Tool Runout in Holder/Spindle, <.0003 TIR Desired