Cutting Tool Insert Troubleshooting

Cratering - Probable Causes:

• Chipbreaker set too tight
• Nose radius is too large
• Side cutting edge angle is too great

Chipping - Probable Causes:

• Lack of rigidity
• Not enough chamfer on the cutting edge
• Chipbreaker too narrow
• Chatter
• Scale or inclusions
• Improper grinding
• Too much relief
• Defective or burred tool holder or shim seat

Torn Finish – Probable Causes

• Lack of rigidity
• Dull tool
• Speed too slow
• Chipbreaker too narrow or too deep
• Improper grinding

Excess Wear – Probable Causes

• Speed too high or feed too light
• Speed too low
• Nose radius is too large
• Improper grinding
  

Chatter – Probable Causes

• Tool is not on-center
• Insufficient relief and/or clearance
• Too much rake
• Too much overhang or tool too small
• Nose radius is too large
• Feed to heavy
• Lack of rigidity
• Insufficient power or slipping clutch

Cracking or Breaking – Probable Causes

• Insert surfaces not flat
• Insert not seated solidly
• Stopping the workpiece while the tool is engaged
• Worn or chipped cutting edges
• Feed to heavy
• Improperly applied coolant
• Too much rake or relief
• Too much overhang or tool too small
• Lack of rigidity in setup
• Speed too slow
• Too much variation in the depth of the cut
• Chatter
• Grinding cracks
• Defective or burred tool holder or shim seat