Here’s a list of common problems encountered in machining operations:

Issue Cause Solution
Tool Break Feed Rate Excessive Increase SFM
Depth of Cut Excessive Reduce Depth of Cut
Excessive Tool Overhang Reduce Tool Stick Out
Excessive Tool Wear Regrind Sooner
Excessive Wear Speed Is Too Fast Decrease Speed
Hard Work Material Change Coating
Wrong Speed/Feed Increase Speed/Feed
Primary Relief Angle Too Low Change to Larger Relief Angle
Recutting Chips Change Feed/Speed/Increase Coolant
Poor Surface Finish Feed Rate Too Fast Correct Feed/Speed Rates
Cutting Speed Too Slow Increase RPM
Recutting Chips Change Feed/Speed/Increase Coolant
Excessive Wear Regrind Sooner
Tool Runout Check Tool Runout in Holder/Spindle
Excessive Tool Overhang Reduce Tool Stick Out
Reduce SFM/Increase IPT
Chip Packing Cut Too Heavy Decrease Depth and Width of Cut
Minimal Chip Clearance End Mill with Fewer Flutes
Lack of Coolant Higher Coolant Pressure/Reposition Nozzle

If you’re looking to purchase quality end mills at affordable prices, or have questions about where to begin, contact our order desk. We’d be happy to take your call and discuss specifics with you.

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