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Application Guide Troubleshooting - Endmills
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Problem Possible Reason
1 Poor workpiece finish Cutting edge wear, cutter radial run-out
2 Splintering of workpiece edge Unsuitable cutting conditions, unsuitable shape of cutting edge
3 Non-parallel or uneven surface Low stiffness of the cutter or of the workpiece (loose)
4 Extreme flank wear 5 Extreme crater wear 6 Breaks and shelling due to thermal shock 7 Formation of built-up edges 8 Poor chip clearance, chip blockage 9 Lack of Rigidity Difficult cutting conditions, clamping of the workpiece
10 End mill cutter breaks Unsuitable cutting conditions, flute length of the cutter
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Unsuitable cutting conditions, unsuitable shape of cutting edge
Solution
increase cutting speed
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reduce cutting speed
increase feed rate
reduce feed rate
reduce cutting depth
change cutter diameter and cut width
check use of cooling lubricant, flush swarf away
increase clearance angle (Radial relief)
increase wedge angle (Rake angle)
increase number of teeth
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reduce number of teeth
select larger chip space (Cutter)
change shape of minor cutting edge
cutter - change radial run-out
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change cutter stiffness, flue length (l/D ratio)
select machine with higher power and stiffness
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