Troubleshooting Cutting Problems
For every problem there is a possible cause and a solution. Here are some typical problems that you may encounter and possible solution for each problem.
Problem |
Cause |
Solution |
| Tool Breakage | Heat buildup due to incorrect tool selection | Use correct tool for material being cut |
| Heat due to inadequate chip removal | Use up spiral tool to help in chip removal | |
| Too high a plunge rate | Reduce plunge rate | |
| Blunt tool | Replace tool | |
| Tool runout | Tighten tool in collet or if necessary change collet | |
| Worn collet | Replace collet | |
| Too high a feed rate | Reduce feed rate | |
| Too high a chip load | Reduce feed rate or increase RPM or change tool to one with more flutes | |
| Vibration | Improve workpiece hold down to machine bed | |
| Tool not fitted correctly in collet | Re-fit tool in collet ensuring at least 80% of collet length is used | |
| Tool deflection | Reduce feed rate but if possible use larger diameter tool | |
| Poor cut finish due to chip rewelding to cut edge | No coolant | Use mist coolant or cold air gun |
| Blunt tool | Replace tool | |
| Too slow a feed rate | Increase feed rate | |
| Incorrect tool selection for material | Choose correct tool for material being machined | |
| Heat due to inadequate chip removal | Use up spiral tool |