Troubleshooting

New or reground toolNon-Factory Reground tools create unknown variable(s)
Feed too highDecrease your FPT
Speed to lowIncrease your RPM’s
Excessive depth of cutDecrease your RDOC
Tool overhang excessiveUse shortest length tool, shortest loc & reduce overhang from tool holder. Depths >4xDia. should move towards a reduced neck tool strategy.
Workpiece RigidityWorkpiece must be 100% secure, the slightest movement (even unseen) will affect tool performance.
Excessive tool runoutRunout (TIR) should be measured at the corner of the tool once the tool is in the holder and in the machine spindle. Our tools require a maximum of .0005 TIR, for maximum tool life.
Hand ground shank flatsHand ground shank flats or Weldon flats induce tool runout and cause premature failure.
Not enough shank contactImperative to have 1.5 -to- 2.0 x Dia. of shank inside tool holder for maximum holding strength.
Part EntryReduce feedrate by 50% at part entry and until tool is 100% engaged into material.
Milling StrategyReview tool path and ensure there are no arbitrary moves, 90-degree corner movements, and any toolpaths that prevent constant radial engagement of the tool or climb milling situations.
Calculate Tool Change IntervalsOnce you have determined tool life on a new tool, it’s good practice to calculate 80-90% of that time and incorporate it as a “safe” tool replacement window.
New or reground toolNon-Factory Reground tools create unknown variable(s)
Speed to highReduce your cutting speed (RPM)
Feed to lowVery common to be too light here, rubbing the tool, so Increase your feed per tooth (FPT)
Depth of cut too lightIncrease your depth of cut (RDOC), but of course this may require lowering your FPT per chip thinning theory.
Tool CoatingEnsure your utilizing the right tool coating for the material.
Workpiece RigidityWorkpiece must be 100% secure, the slightest movement (even unseen) will affect tool performance
Wrong cutting parameters for hardnessKnow the Rockwell hardness of your workpiece, Speeds n feeds are adjusted to the hardness the tool is cutting.
Excessive tool runoutRunout (TIR) should be measured at the corner of the tool once the tool is in the holder and in the machine spindle. Our tools require a maximum of .0005 TIR, for maximum tool life.
Recutting chipsEnsure coolant spray is directed with tool rotation and chip flight direction.
Low Flute countIncrease your flute count helping to broaden the wear/load on a larger number of flutes.
Incorrect primary relief for materialTools have radial relief to lower friction, if its too high for a harder material flank wear will propegate swiftly. Ensure tool is recommended for your material.
New or reground toolNon-Factory Reground tools create unknown variable(s)
No tool radius usedAlso utilize a corner radius when possible, this strengthens the corner of the tool and increases tool life.
Low depth of cutDepth of cut is not meeting or exceeding size of the corner radius which puts pressure on only a select portion of the corner radius, causing stress points on tool corner.
Speed too highLower your cutting speed (RPM)
Wrong cutting parameters for hardnessKnow the Rockwell hardness of your workpiece, Speeds n feeds are adjusted to the hardness the tool is cutting.
Excessive tool runoutRunout (TIR) should be measured at the corner of the tool once the tool is in the holder and in the machine spindle. Our tools require a maximum of .0005 TIR, for maximum tool life.
Not enough shank contactImperative to have 1.5 -to- 2.0 x Dia. of shank inside tool holder for maximum holding strength.
Workpiece RigidityWorkpiece must be 100% secure, the slightest movement (even unseen) will affect tool performance.
Slower HelixReduce your helix angle if possible, as this will lower the rake/shear at the corner and provide a stronger corner.
Higher flute countIncrease the flute count helping to broaden the wear/load on a larger number of flutes.
New or reground toolNon-Factory Reground tools create unknown variable(s)
Speed to highReduce your cutting speed (RPM)
Variable pitch toolingUtilize our variable pitch tooling when applicable, as this will help to reduce or eliminate the harmonic signature that chatter develops from.
Feed to lowVery common to be too light here(Hence: rubbing the tool), so increase your feed per tooth (FPT).
Tool not stabilizedEither increase your FPT and/or your RDOC to help stabilize the cutter in the cut.
Workpiece rigidityWorkpiece must be 100% secure, the slightest movement (even unseen) will affect tool performance.
Not enough shank contactImperative to have 1.5 -to- 2.0 x Dia. of shank inside tool holder for maximum holding strength.
Tool Holder rigidityCritical to have a very accurate tool holder, that also utilizes full shank contact & maximum holding strength.
Excessive tool runoutRunout (TIR) should be measured at the corner of the tool once the tool is in the holder and in the machine spindle. Our tools require a maximum of .0005 TIR, for maximum tool life.
Too much tool contact engagementThis is the amount of contact the tool is experiencing while in the cut, reduce your RDOC and this measurement will decrease.
New or reground toolNon-Factory Reground tools create unknown variable(s)
Chip Size UnmanageableUtilize our chip breaker tools. Look in our catalog (pgs. 6-9) to see our selections. These will usually break chips to 1/2 the length your experiencing now.
Too high flute countLower the flute count on your tool to open up chip evacuation room.
Feed too highDecrease your FPT
Too heavy RDOCLower your RDOC but remember you may need to increase your FPT to accommodate proper chip thinning theory.
Proper coolant flushNot too much and not too little. Theres a fine line here to ensure your providing enough coolant flush but not overdoing it (as it can create a vortex effect around the tool). Also ensure the lines are in the direction of the chip flight direction, and not spraying into it.
New or reground toolNon-Factory Reground tools create unknown variable(s)
Tool overhang excessiveUse shortest length tool, shortest loc & reduce overhang from tool holder. Depths >4xD should move towards a reduced neck tool strategy.
Increase flute countIncreasing your flute count, increases the core diameter of the tool lessening tool deflection. Caution, as this also creates more tool contact with wall.
Tool heavy of a depth of cutLighten up the RDOC, but never reach lower than 3% of tool diameter as this will induce tool rubbing.
Too thin of a chipIncrease your FPT, per chip thinning theory and overcome possible tool rubbing conditions.
Custom GeometryAs a custom tool manufacturer we can look at the exact material your cutting and design a custom tool that will be freer cutting to lessen deflection.
Tool runout excessiveRunout (TIR) should be measured at the corner of the tool once the tool is in the holder and in the machine spindle. Our tools require a maximum of .0005 TIR, for maximum tool life.
Wall/floor contactDual contact can institute tool deflection, when finishing walls good practice to raise tool .010 above floor then come back to blend transition.
New or reground toolNon-Factory Reground tools create unknown variable(s)
Speed to lowIncrease your RPM’s
Feed too highDecrease your FPT, but always maintain chip thinning procedures to avoid tool rubbing.
RDOC too lowIn some cases too light of a RDOC can affect surface finish, might be an option to increase your RDOC. 3-5% of diameter is a good starting point.
Too high surface contactLessen the flute count as this will lower your tool-to-part contact increasing your finish. In steels 5-flutes is a great middle ground for a good finisher. High walls might require higher number of flutes due to the increase of core strength in tool.
Too low coolant %Increase the proportion of mixture, going to a 12-13% concentration will contribute to a better surface finish.
Built up edgeAs seen on the cutting edges, increase your FPT, utilize proper coatings and check your coolant strategy in order to lower the BUE the tool is experiencing.
New or reground toolNon-Factory Reground tools create unknown variable(s)
No corner radiusUtilize tools with a corner radius size that is 6-10% of diameter
Speed to lowIncrease your RPM’s
Feed too highDecrease your FPT, but always maintain chip thinning procedures to avoid tool rubbing.
RDOC too lowIn some cases too light of a RDOC can affect surface finish, might be an option to increase your RDOC, with 5% of diameter as a good starting point.
No dish on end of toolGood floor finishing requires dish (or end concavity) at the end of the tool. This allows for freer cutting and proper end geometry chip evacuation.
Too low coolant %Increase the proportion of mixture, going to a 12-13% concentration will contribute to a better surface finish.
Wiper flatsWiper flats on Non-ferrous tooling can help with more of a burnishing effect and increased part finish on floors. Corner radius tools have this effect as well.
New or reground toolNon-Factory Reground tools create unknown variable(s)
Chip welding to OD of tool/cutting edgeUtilize proper tool coating for material your cutting
Feed to lowIncrease your FPT
Speed to lowIncrease your RPM’s
Proper coolant flushNot too much and not too little. There’s a fine line here to ensure your providing enough coolant flush but not overdoing it (as it can create a vortex effect around the tool). Also ensure the lines are in the direction of the chip flight direction, and not spraying into it.
Too low coolant %Increase the proportion of mixture, going to a 12-13% concentration will contribute to a better surface finish.
Milling strategyEnsure your climb milling

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