Category
|
Problem
|
Cause
|
Remedy
|
Threading with Dies
|
Poor finish (5/5)
|
Bar end not chamfered
|
Ensure bar end is chamfered
|
Reaming
|
Rapid Tool Wear
|
Insufficient stock to remove
|
Increase the amount of stock to be removed
|
Threading with Dies
|
Rapid wear (1/2)
|
Incorrect/lack of lubricant
|
Adjust conditions
|
Threading with taps
|
Rapid wear (1/3)
|
Wrong type of tap for application
|
Use tap with lower rake angle and/or higher relief and/or longer chamfer. Use coated tool.
|
Threading with Dies
|
Rapid wear (2/2)
|
Speed too high
|
Adjust conditions
|
Threading with taps
|
Rapid wear (2/3)
|
Lack of lubricant
|
Use good lubrication in order to prevent built up edge and thermal stress on cutting edge.
|
Threading with taps
|
Rapid wear (3/3)
|
Tap speed too high
|
Reduce cutting speed.
|
Counterboring and Countersinking
|
Rough Finish (1/2)
|
Dull cutting edge
|
Resharpen to original tool geometry
|
Counterboring and Countersinking
|
Rough Finish (2/2)
|
Wrong feeds & speeds
|
Increase speed - also try reducing feed
|
Milling
|
Short Tool Life (1/3)
|
Tough work material
|
Select the suitable tool
|
Thread milling
|
Short tool life (1/3)
|
Wrong cutting data
|
Reduce speed/feed
|
Counterboring and Countersinking
|
Short Tool Life (1/5)
|
Excessive cratering
|
Increase speed or decrease feed
|
Milling
|
Short Tool Life (2/3)
|
Improper cutting angle and primary relief
|
Change to correct cutting angle
|
Thread milling
|
Short tool life (2/3)
|
Instability
|
Check tool holder
|
Counterboring and Countersinking
|
Short Tool Life (2/5)
|
Abrasive material
|
Decrease speed and increase feed Increase coolant flow
|
Milling
|
Short Tool Life (3/3)
|
Cutter/workpiece friction
|
Use coated tool
|
Thread milling
|
Short tool life (3/3)
|
Rapid wear
|
Reduce speed
|
Counterboring and Countersinking
|
Short Tool Life (3/5)
|
Hard materials
|
Reduce speed - rigidity very important
|
Counterboring and Countersinking
|
Short Tool Life (4/5)
|
Insuffi cient chip room
|
Use larger diameter tool
|
Counterboring and Countersinking
|
Short Tool Life (5/5)
|
Delayed resharpening
|
Prompt resharpening to original geometry will increase tool life
|
Drilling
|
Spiral finish in hole (1/2)
|
Insufficient feed
|
Increase feed
|
Drilling
|
Spiral finish in hole (2/2)
|
Bad positional accuracy
|
Use a spot drill before drilling
|
Drilling
|
Splitting of the web (1/4)
|
Feed too high
|
Reduce feed to optimum rate
|
Drilling
|
Splitting of the web (2/4)
|
Insufficient initial clearance
|
Regrind to correct specification
|
Drilling
|
Splitting of the web (3/4)
|
Excessive web thinning
|
Regrind to correct specification
|
Drilling
|
Splitting of the web (4/4)
|
Heavy impact at point of drill
|
Avoid impact at the point of drill. Take care with taper shank drills when inserting / ejecting them from a spindle
|
Reaming
|
The tool clamps and breaks (1/6)
|
Worn out tool
|
Regrind to correct specification
|
Reaming
|
The tool clamps and breaks (2/6)
|
Back taper of the tool is too small
|
Check and replace / modify the tool
|
Reaming
|
The tool clamps and breaks (3/6)
|
The width of the land is too wide
|
Check and replace / modify the tool
|
Reaming
|
The tool clamps and breaks (4/6)
|
Workpiece material tend to squeeze
|
Use an adjustable reamer to compensate for the displacement
|
Reaming
|
The tool clamps and breaks (5/6)
|
Pre-drilled hole is too small
|
Decrease the amount of stock to be removed
|
Reaming
|
The tool clamps and breaks (6/6)
|
Heterogeneous material with hard inclusions
|
Use solid carbide reamer
|
Threading with taps
|
Undersize (1/5)
|
Wrong type of tap for application
|
Use spiral point for through hole or spiral flute for blind hole. Use coated tool to prevent built up edge. Use tap with higher rake angle
|
Threading with taps
|
Undersize (2/5)
|
Incorrect tolerance
|
Choose a tap with higher tolerance, especially on material with low oversize tendency, such as cast iron, stainless steel
|
Threading with taps
|
Undersize (3/5)
|
Incorrect or lack of lubricant
|
Use good lubrication in order ot prevent chip blockage inside the hole.
|
Threading with taps
|
Undersize (4/5)
|
Tap drill hole too small
|
Increase drill diameter to the maximum value.
|
Threading with taps
|
Undersize (5/5)
|
Material closing in after tapping
|
Adjust conditions
|
Reaming
|
Undersize hole (1/5)
|
Insufficient stock to remove
|
Increase the amount of stock to be removed
|
Reaming
|
Undersize hole (2/5)
|
Too much heat generated while reaming. The hole widens and shrinks.
|
Increase coolant flow
|
Reaming
|
Undersize hole (3/5)
|
The tool diameter is worn and is undersize
|
Regrind to correct specification
|
Reaming
|
Undersize hole (4/5)
|
Too low feed or cutting speed
|
Adjust cutting conditions
|
Reaming
|
Undersize hole (5/5)
|
Pre-drilled hole is too small
|
Decrease the amount of stock to be removed
|
Milling
|
Wear (1/5)
|
Workpiece material too hard
|
Choose correct tool with higher grade material and/or proper coating
|
Milling
|
Wear (2/5)
|
Improper feed and speed
|
Adjust cutting conditions
|
Milling
|
Wear (3/5)
|
Poor chip evacuation
|
Reposition coolant lines
|
Milling
|
Wear (4/5)
|
Conventional milling
|
Climb milling
|
Milling
|
Wear (5/5)
|
Improper cutter helix
|
Select the suitable tool
|
Milling
|
Workpiece inaccuracy (1/5)
|
Tool deflection
|
Choose a shorter tool and/or place shank further up holder
|
Milling
|
Workpiece inaccuracy (2/5)
|
Insufficient number of flutes
|
Use a tool with more flutes
|
Milling
|
Workpiece inaccuracy (3/5)
|
Loose/worn tool holder
|
Repair or replace it
|