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Milling Troubleshooting - Frequently Asked Questions

ProblemCauseSolution
Chipping
  • Feed rate too high
  • Chattering
  • Loose tool
  • Tool rigidity
  • Low cutting speed
  • Loose toolholder
  • Reduce feed rate
  • Reduce RPM
  • Remove, clean, and retighten
  • Shorten LOC, place shank further up holder
  • Increase RPM
  • Remove from spindle, clean and replace
Wear
  • High cutting speed
  • Low feed rate
  • Poor chip evacuation
  • Hard material
  • Reduce RPM
  • Increase feed rateu
  • Reposition coolant lines, use air blasting
  • Change to recommended helix angle
  • Use coated tool
Breakage
  • Excessive spindle TIR
  • Feed rate too high
  • Depth of cut too large
  • Poor tool rigidity
  • Tool wear
  • Poor chip evacuation
  • Reduce feed rate
  • Reduce depth of cut
  • Shorten LOC, place shank further up holder
  • Replace/regrind sooner
  • Use air blasting
Chattering
  • Speed and feed too high
  • Poor toolholder rigidity
  • Poor spindle rigidity
  • Workpiece rigidity
  • Relief angle too high
  • Depth of cut too large
  • Poor tool rigidity
  • Reduce feed rate
  • Replace with shorter/more rigid holder
  • Use larger spindle or different machine tool
  • Tighten workpiece holding method
  • Regrind with smaller relief angle
  • Reduce depth of cut
  • Shorten LOC, place shank further up holder
Chip Packing
  • Feed rate too high
  • Low cutting speed
  • Insufficient chip room
  • Reduce feed rate or increase speed
  • Increase RPM or reduce feed rate
  • Use tool with less flutes, increase helix
Poor Surface Finish
  • Feed rate too high
  • Low cutting speed
  • Tool wear
  • Edge build up
  • Depth of cut too large
  • Chip welding
  • Reduce feed rate
  • Increase RPM
  • Replace or regrind tool
  • Increase RPM, switch to higher helix tool
  • Reduce depth of cut
  • Increase volume of coolant
Burring or Workpiece Chipping
  • Excessive spindle TIR
  • Tool wear
  • Improper helix angle
  • Feed rate too high
  • Depth of cut too large
  • Replace or regrind tool
  • Change to recommended helix angle
  • Reduce feed rate
  • Reduce depth of cut
Workpiece Inaccuracy
  • Loose/worn toolholder
  • Poor toolholder rigidity
  • Poor spindle rigidity
  • Insufficient number of flutes
  • Tool deflection
  • Repair or replace
  • Replace with shorter/more rigid toolholder
  • Use larger spindle or different machine tool
  • Use tool with higher flute quantity
  • Shorten LOC, place shank further up holder