Troubleshooting for End Milling
| # | Failure | Cause | Countermeasures |
|---|---|---|---|
| Cutting Edge Failure | |||
| 1 | Excessive Wear | Cutting Conditions • Cutting speed is too fast • Feed rate is too large |
• Decrease cutting speed and feed rate |
| Tool Shape • The flank relief angle is too small |
• Change to an appropriate flank relief angle | ||
| Tool Material • Insufficient wear resistance |
• Select a more wear-resistant substrate • Use a coated tool |
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| 2 | Chipping | Cutting Conditions • Feed rate is too large • Depth of cut is too large • Tool overhang is too long |
• Decrease cutting speed • Reduce depth of cut • Adjust tool overhang to the correct length |
| Machine Area • Workpiece clamping is too weak • Tool mounting is unstable |
• Clamp the workpiece firmly • Make sure the tool is seated in the chuck properly |
||
| 3 | Fracture | Cutting Conditions • Feed rate is too large • Depth of cut is too large • Tool overhang is too long • Cutting edge is too long |
• Decrease cutting speed • Reduce depth of cut • Reduce tool overhang as much as possible • Select a tool with a shorter cutting edge |
| Tool Shape • Web thickness is too small |
• Change to more appropriate web thickness | ||
| Others | |||
| 1 | Deflection in Wall Surface | Cutting Conditions • Feed rate is too large • Depth of cut is too large • Tool overhang is too long • Cutting on the down-cut |
• Decrease cutting speed • Reduce depth of cut • Adjust tool overhang to the correct length • Change direction to up-cut |
| Tool Shape • Helix angle is too large • Web thickness is too small |
• Use a tool with a smaller helix angle • Use a tool with the appropriate web thickness |
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| 2 | Unsatisfactory Machined Surface Finish | Cutting Conditions • Feed rate is too large • Chip biting |
• Decrease cutting speed • Use air blow • Use an insert with a larger relief pocket |
| 3 | Chattering | Cutting Conditions • Cutting speed is too fast • Cutting on the up-cut • Tool overhang is too long |
• Decrease the cutting speed • Change direction to down-cut • Adjust tool overhang to the correct length |
| Tool Shape • Rake angle is too large |
• Use a tool with an appropriate rake angle | ||
| Machine Area • Workpiece clamping is too weak • Tool mounting is unstable |
• Clamp the workpiece firmly • Make sure the tool is seated in the chuck properly |
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| 4 | Chip Blockage | Cutting Conditions • Feed rate is too large • Depth of cut is too large |
• Decrease cutting speed • Reduce depth of cut |
| Tool Shape • Too many teeth • Chip biting |
• Reduce number of teeth • Use air blow |
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