Trouble shooting in Milling
Please refer to as below for commonly seen issues |
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| Trouble | Possible causes | Solutions |
| Chipping | ▪ Feed too high (fz). ▪ Up milling. ▪ Chattering. ▪ Too much overhang. |
▪ Reduce feed (fz). ▪ Try down milling instead. ▪ Reduce feed rate or Speed / check holder & fixture. ▪ Adjust to minimize overhang. |
| Wear | ▪ High cutting speed. ▪ Feed too low. ▪ Up milling. ▪ High hardened work piece. |
▪ Decrease cutting speed. ▪ Increase feed. ▪ Down milling. ▪ Choosing corresponding coating insert. |
| Tool Breakage | ▪ Too much cutting amount. ▪ High cutting force. ▪ Too much overhang. |
▪ Decrease cutting amount (Ap/Ae). ▪ Lower down feed (fz), increase spindle speed. ▪ Adjust to minimize overhang. |
| Surface Roughness | ▪ Chattering. ▪ Generation of bulit-up edge (BUE). ▪ Feed too high, speed too low. |
▪ Reduce feed rate or Speed / check holder & fixture. ▪ Increasing cutting speed & feed rate, or try down milling. ▪ Reduce feed & increase speed. |
| Accuracy of Finished | ▪ Deflection of tool. |
▪ Using big diameter tool & minimize the overhang. |
