| Category | Problem | Cause | Remedy |
|---|---|---|---|
| Thread milling | Chipping (2/3) | Wrong cutting data | Reduce speed/feed |
| Counterboring and Countersinking | Chipping (2/3) | Recutting work hardened chips | Increase coolant flow |
| Milling | Chipping (2/6) | Chattering | Reduce the RPM |
| Threading with taps | Chipping (2/7) | Incorrect or lack of lubricant | Use good lubrication in order to prevent built up edge. |
| Thread milling | Chipping (3/3) | Load too big | Reduce feed or Divide cut into 2 or 3 passes |
| Counterboring and Countersinking | Chipping (3/3) | Vibration | Increase rigidity of set-up, especially worn tool holders |
| Milling | Chipping (3/6) | Low cutting speed | Increase the RPM |
| Threading with taps | Chipping (3/7) | Taps hit bottom of hole | Increase depth of drilling or decrease depth of tapping |
| Milling | Chipping (4/6) | Conventional milling | Climb milling |
| Threading with taps | Chipping (4/7) | Work hardening surface | Reduce speed, use coated tool, use good lubrication. |
| Milling | Chipping (5/6) | Tool rigidity | Choose a shorter tool and/or place shank further up holder |
| Threading with taps | Chipping (5/7) | Swarf trapping on reversal | Avoid sudden return of tap on reversal motion |
| Milling | Chipping (6/6) | Workpiece rigidity | Hold workpiece tightly |
| Threading with taps | Chipping (6/7) | Chamfer hits hole entrance | Check axial position and reduce axial error of tap point on hole centre. |
| Threading with taps | Chipping (7/7) | Tap drill hole too small | Increase drill diameter to maximum value. |
| Threading with Dies | Chipping / Breakage (1/5) | Wrong type of die | Select the suitable die |
| Threading with Dies | Chipping / Breakage (2/5) | Speed too high | Adjust conditions |
| Threading with Dies | Chipping / Breakage (3/5) | Bar diameter too large | Reduce to appropriate size |
| Threading with Dies | Chipping / Breakage (4/5) | Bar end not chamfered | Ensure bar end is chamfered |
| Threading with Dies | Chipping / Breakage (5/5) | Misalignment | Correct alignment, ensure cleanliness |
| Counterboring and Countersinking | Excessive Cutting Edge Wear (1/3) | Incorrect feeds & speeds | Increase feed - especially when machining ductile or free machining materials. Also try reducing speed |
| Counterboring and Countersinking | Excessive Cutting Edge Wear (2/3) | Rough cutting edge | Lightly hone cutting edge with fine grit diamond hone |
| Counterboring and Countersinking | Excessive Cutting Edge Wear (3/3 | Insufficient coolant | Increase coolant flow - review type of coolant |
| Counterboring and Countersinking | Glazed Finish (1/3) | Feed too light | Increase feed |
| Counterboring and Countersinking | Glazed Finish (2/3) | Dull cutting edge | Resharpen tool to original geometry |
| Counterboring and Countersinking | Glazed Finish (3/3) | Insufficient clearance | Resharpen tool with more clearance |
| Drilling | Hole size too large (1/2) | Incorrect point geometry | Check point geometry in regrinding section |
| Drilling | Hole size too large (2/2) | Ineffective swarf clearance | Adjust speed, feed and peck length to achieve more manageable swarf |
| Reaming | Oval and conical holes (1/3) | Displacement in the machine spindle | Repair and rectify spindle displacement |
| Reaming | Oval and conical holes (2/3) | Misalignment between tool and hole | Use a bridge reamer |
| Reaming | Oval and conical holes (3/3) | Asymmetric bevel lead angle | Regrind to correct specification |
| Threading with taps | Oversize (1/6) | Incorrect tolerance | Choose a tap with lower thread tolerance |
| Threading with taps | Oversize (2/6) | Incorrect axial feed rate | Reduce feed rate by 5-10% or increase compression of tap holder |
| Threading with taps | Oversize (3/6) | Wrong type of tap for application | Use spiral point for through hole or spiral fl ute for blind hole. Use coated tool to prevent built up edge. Check Catalogue or Product Selector for correct tool alternative |
| Threading with taps | Oversize (4/6) | Tap not centered on the hole | Check tap holder and position tap centre on the hole |
| Threading with taps | Oversize (5/6) | Lack of lubrication | Use good lubrication in order to prevent built up edge. |
| Threading with taps | Oversize (6/6) | Tap speed too slow | Adjust conditions |
| Threading with Dies | Oversize / Undersize (1/2) | Misalignment | Correct alignment, ensure cleanliness |
| Threading with Dies | Oversize / Undersize (2/2) | Incorrect axial feed rate | Ensure axial feed rate is controlled accurately |
| Reaming | Oversize Hole (1/7) | Excessive lip height variation | Regrind to correct specification |
| Reaming | Oversize Hole (2/7) | Displacement in the machine spindle | Repair and rectify spindle displacement |
| Reaming | Oversize Hole (3/7) | Defects on the tool holder | Replace tool holder |
| Reaming | Oversize Hole (4/7) | Tool shank is damaged | Replace or regrind the shank |
| Reaming | Oversize Hole (5/7) | Ovality of the tool | Replace or regrind the tool |
| Reaming | Oversize Hole (6/7) | Asymmetric bevel lead angle | Regrind to correct specification |
| Reaming | Oversize Hole (7/7) | Too high feed or cutting speed | Adjust cutting conditions |
| Threading with Dies | Poor finish (1/5) | Incorrect rake angle for the material | Try alternative dies or special die |
| Threading with Dies | Poor finish (2/5) | Incorrect/lack of lubricant | Adjust conditions |
| Threading with Dies | Poor finish (3/5) | Incorrect speed | Adjust conditions |
| Threading with Dies | Poor finish (4/5) | Bar diameter too large | Reduce to appropriate size |