Calculators & Utilities
Troubleshooting for Carbide End Mills
| PROBLEM | CAUSE | SOLUTION |
|---|---|---|
| Chip Packing |
Feed per tooth too high Not enough chip room Not enough coolant |
Lower feed rate Use end mill fewer flutes Use more coolant to flush out chips |
| Rough finish |
Feed too fast Slow speed Too much wear Feed per tooth too high |
Slow down to correct feed Use higher speed Regrind sooner Lower feed rate |
| Burr |
Dull cutting edge Improper cutting angle |
Regrind sooner Change to correct cutting angle |
| Wandering |
Machine/Holder runout Not enough rigidity in machine/holder Not enough flutes Tool deflection |
Repair machine or holder Change machine or holder Use end mill with more flutes Choke up on shank or reduce feed rate |
| Chipping |
Feed too fast Feed too fast on first cut Not enough rigidity of machine/holder Loose holder Loose vise Lack of rigidity (tool) Teeth too sharp |
Lower feed rate Lower feed on intial contact Change to rigid machine/holder Tighten tool holder Tighten workpiece fixture Choke up on shank; use shorter tool Choose tool with correct primary relief angle |
| Wear |
Speed too fast Hard material Feed too slow Improper cutting angle Primary relief angle too small |
Slow down speed, use more coolant Use better grade for cutter material, add coating Increase feed speed Change to correct cutting angle Increase primary relief angle |
| Breakage |
Feed too fast Chip load per tooth too great Flute length too long Long overall length Too much wear |
Slow down feed Adjust to smaller chip load per tooth Choke up on shank Use shorter end mill Regrind sooner |
| Chattering |
Feed and speed too fast Poor rigidity of machine/holder Relief angle too large Loose workpiece holder Cutting too deep Flute length too long Long overall length |
Adjust feed and speed Use better machine/holder Change to smaller relief angle Hold workpiece tighter Change to smaller depth of cut Choke up on shank Use shorter end mill |
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