| Insert wear appears high (flank wear) |
- Not enough chip load
- Surface footage is high
- Incorrect grade or coating
|
- Verify correct speed and feed
- Increase feed rate
- Decrease RPM
- Consider different insert
|
| Insert chipping |
- Surface footage is low
- Incorrect grade or coating
- Using sharp edge insert incorrectly
- Feed too high
|
- Verify correct speed and feed
- Increase spindle speed
- Decrease feed rate
- Change insert selection
- Decrease DOC
|
| Built-up edge on insert |
- Low surface footage
- Light chip load (feed per tooth)
- Incorrect coating
|
- Verify correct speed and feed
- Increase cutting speed
- Increase feed rate
- Select different coating
|
| Poor finish/chatter |
- Cutter hung out too far
- Excessive runout
- Inadequate tool holding
|
- Use Carbide Core cutter body
- Reduce tool gage length
- Check tool holder wear
- Use high-rigidity tool holder
|
| Tool shank breaks |
- Tool pressure too great
- Fatigued cutter body
|
- Decrease DOC
- Reduce tool gage length
- Decrease feed rate
|
