Page 712 - Master Catalog 2017, Inch

Technical Information
Failure and Solution Guide

problem cause possible solution
thread with torn fi nish
• Use modifi ed fl ank infeed.
• Use full profi le insert.
• Burs. • Increase coolant concentration.
• Torn fi nish.
• Steps. • Increases SFM.
• Check machine “Z” travel axis.
• Improper shim. • Check insert form.
• Improper infeed.
• Check for correct shim in LT system.
• Calculate fl ank clearance.
chatter
• Use modifi ed fl ank infeed.
• Poor rigidity. • Minimize tool overhang.
• Insert movement. • Check for workpiece defl ection.
• Improper infeed. • Check insert and clamp.
• Off centerline. • Verify that tool cutting position is at workpiece centerline.
• Adjust number of passes. Fewer passes reduce chatter.

built-up edge
• Increase SFM.
• Speed too low.
• Insuffi cient coolant. • Increase coolant concentration and/or fl ow.
• Adjust infeed angle.
• Chip load.
• Increase depth of cut per pass.
deformation
• Wrong grade. • Use modifi ed fl ank infeed.
• Speed too high. • Use a more wear-resistant grade (e.g., TN6010 ™ ).
• Improper infeed angle. • Reduce SFM.
• Insuffi cient coolant. • Increase coolant fl ow.

chipping
• Use modifi ed fl ank infeed.
• Increase or decrease number of passes.
• Eliminate spring passes.
• Use tougher grade (e.g., TN6025 ™ ).
• Improper infeed. • Increase SFM if chipping on trailing edge.
• Chip load. • Decrease SFM if chipping on leading edge.
• Wrong grade. • Minimize tool overhang.
• Incorrect speed. • Check for insert movement/check clamp. Torque screw
• Poor rigidity.
or clamp to correct value.
• Check for possible part defl ection.
• Calculate fl ank clearance.
• Ensure correct shim.

broken nose
• Heavy chip load. • Use modifi ed fl ank infeed.
• Small nose radius. • Decrease chip load.
• Wrong grade. • Use large nose radius if possible.
• Improper infeed. • Use tougher grade (e.g., TN6025).

fl ank wear • Ensure correct shim.
• Improper shim. • Use a more wear-resistant grade (e.g., TN6025).
• Wrong grade. • Increase coolant fl ow.
• Insuffi cient coolant. • Check the centerline height of the tool. (The smaller the
• Off centerline. diameter, the more critical the need for centerline accuracy.)
• Insuffi cient fl ank clearance. • Calculate fl ank clearance and change shim to increase
• Improper infeed angle. clearance on worn fl ank.
• If wear is on trailing fl ank, increase infeed angle clearance.

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