| Category | Problem | Cause | Remedy |
|---|---|---|---|
| Reaming | Bad Hole finish (1/6) | Excessive stock to remove | Decrease the amount of stock to be removed |
| Reaming | Bad Hole finish (2/6) | Worn out tool | Regrind to specification |
| Reaming | Bad Hole finish (3/6) | Too small cutting rake angle | Regrind to specification |
| Reaming | Bad Hole finish (4/6) | Too diluted emulsion or cutting oil | Increase % concentration |
| Reaming | Bad Hole finish (5/6) | Feed and/or speed too low | Adjust cutting conditions |
| Reaming | Bad Hole finish (6/6) | Cutting speed too high | Adjust cutting conditions |
| Milling | Bad Surface finish (1/6) | Feed too fast | Slow down to correct speed |
| Milling | Bad Surface finish (2/6) | Speed too slow | Increase the speed |
| Milling | Bad Surface finish (3/6) | Chip biting | Decrease stock removal |
| Milling | Bad Surface finish (4/6) | Tool wear | Replace or regrind the tool |
| Milling | Bad Surface finish (5/6) | Edge build up | Change to higher helix tool |
| Milling | Bad Surface finish (6/6) | Chip welding | Increase coolant quantity |
| Milling | Breakage (1/3) | Too high stock removal | Decrease feed per tooth |
| Threading with taps | Breakage (1/8) | Tap worn out | Use a new tap or regrind the old one |
| Milling | Breakage (2/3) | Feed too fast | Slow down feed |
| Threading with taps | Breakage (2/8) | Lack of lubricant | Use good lubrication in order to prevent built up edge and chip blockage. |
| Milling | Breakage (3/3) | Flute length or overall length too long | Hold shank deeper, use shorter end mill |
| Threading with taps | Breakage (3/8) | Taps hit bottom of hole | Increase depth of drilling or decrease depth of tapping |
| Threading with taps | Breakage (4/8) | Tap speed too high | Reduce cutting speed. |
| Threading with taps | Breakage (5/8) | Work hardening surface | Reduce speed. Use coated tool Use good lubrication. |
| Threading with taps | Breakage (6/8) | Tap drill hole too small | Increase drill diameter up to maximum value. |
| Threading with taps | Breakage (7/8) | Too high torque | Use tapping attachment with torque adjustment clutch |
| Threading with taps | Breakage (8/8) | Material closing in after tapping | Adjust conditions |
| Drilling | Breakage at flute run out (1/2) | Choking of flutes | Adopt a peck / series drilling concept |
| Drilling | Breakage at flute run out (2/2) | Drill slipping | Ensure the drill is held securely in the chuck and spindle |
| Thread milling | Broken cutter (1/3) | Bad chip evacuation | Use compressed air, emulsion or internal coolant |
| Thread milling | Broken cutter (2/3) | Load too big | Reduce feed or Divide cut into 2 or 3 passes |
| Thread milling | Broken cutter (3/3) | Instability | Check/change tool holder |
| Reaming | Broken or twisted tangs | Incorrect fit between shank and socket | Ensure the shank and the socket are clean and free from damage |
| Drilling | Broken or twisted tangs | Bad fit between shank and socket | Ensure the shank and socket are clean and free from damage |
| Drilling | Broken outer corners | Unstable component set up | Reduce movement in the component |
| Threading with Dies | Built up edge (1/3) | Incorrect/lack of lubricant | Adjust conditions |
| Threading with taps | Built up edge (1/4) | Wrong type of tap for application | Use tap with lower rake angle and/or higher relief. |
| Threading with Dies | Built up edge (2/3) | Bar diameter too large | Reduce to appropriate size |
| Threading with taps | Built up edge (2/4) | Lack of lubricant | Use good lubrication in order to prevent built up edge. |
| Threading with Dies | Built up edge (3/3) | Speed too low | Adjust conditions |
| Threading with taps | Built up edge (3/4) | Surface treatment not suitable | Adjust conditions |
| Threading with taps | Built up edge (4/4) | Tap speed too low | Adjust conditions |
| Counterboring and Countersinking | Chattering (1/2) | Insufficient machine horsepower | Use tool with fewer flutes as correct feeds & speeds must be maintained |
| Milling | Chattering (1/5) | Feed and speed too high | Adjust cutting conditions |
| Counterboring and Countersinking | Chattering (2/2) | Vibration | Resharpen tool with more clearance |
| Milling | Chattering (2/5) | Flute or overall length too long | Hold shank deeper and use shorter end mill |
| Milling | Chattering (3/5) | Cutting too deep | Decrease depth of cut |
| Milling | Chattering (4/5) | Not enough rigidity (machine and holder) | Check the tool holder and change it if necessary |
| Milling | Chattering (5/5) | Workpiece rigidity | Hold workpiece tightly |
| Drilling | Chipped cutting lips | Excessive initial clearance | Regrind to correct specification |
| Thread milling | Chipping (1/3) | Instability | Check/change tool holder |
| Counterboring and Countersinking | Chipping (1/3) | Poor chip removal | Use tool with larger flute space - larger diameter or fewer flutes |
| Milling | Chipping (1/6) | Feed rate too high | Reduce feed rate |
| Threading with taps | Chipping (1/7) | Wrong type of tap for application | Choose a tap with lower rake angle. Choose a tap with longer chamfer. Use spiral point taps for through hole and spiral fl ute for blind holes, in order to avoid chip blockage. |