| CARBIDE END MILL TROUBLE SHOOTING |
| ISSUE |
CAUSE |
CAUSE |
| Poor surface finish |
Incorrect feed rate |
Reduce feed rate |
| Incorrect speed |
Adjust according to recommendations |
| Incorrect ap |
Reduce ap |
| Tool wear |
Replace tool or sharpen tool |
| Breakage |
Incorrect feed rate |
Reduce feed rate |
| Incorrect Ap |
Reduce Ap |
| Incorrect tool overhang |
Reduce tool overhang |
| Incorrect tool |
Use bigger diameter tool |
| Chipping |
Incorrect feed rate |
Reduce feed rate |
| Incorrect speed |
Adjust according to recommendations |
| Loose tool holder |
Tighten tool holder |
| Incorrect feed direction |
Change cut path |
| Low work piece rigidty |
Replace tool holder |
| Incorrect tool overhang |
Reduce tool overhang |
| Chattering |
Incorrect feed rate |
Reduce feed rate |
| Incorrect speed |
Adjust according to recommendations |
| Low tool holder |
Replace tool holder |
| Incorrect ap |
Reduce ap |
| Incorrect geometry |
Use large helix angle tool |
| Incorrect tool overhang |
Reduce tool overhang |
| Wear |
Incorrect feed rate |
Reduce feed rate |
| Incorrect speed |
Adjust according to recommendations |
| Short tool life |
Use matchable & coated tool |
| Incorrect feed direction |
Change cut path |
| Poor coolant condition |
Replace coolant |
| Poor chip evacuation |
Incorrect feed rate |
Reduce feed rate |
| Incorrect speed |
Adjust according to recommendations |
| Insufficient coolant |
Increase coolant volume |
| Incorrect geometry |
Use large helix angle tool |