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Groove-Turn & Parting
ISO Turn
Threading
Milling
Hole making
Products Main Page
>
Insert Wear Problems and Solutions
>
Threading Inserts Wear Problems and Solutions
Threading Inserts Wear Problems and Solutions
Turn Thread
Mill Thread
Type of Wear
×
Plastic Deformation
Plastic Deformation
Cause
Excessive heat in cutting zone
Wrong grade
Inadequate coolant supply
Depth of cut too large
Cutting speed too high
Nose radius too small
Remedy
Reduce RPM/reduce depth of cut/check turned dia.
Use coated grade/use harder grade
Apply coolant
Reduce depth of cut /increase no. of passes
Reduce cutting speed
If possible use insert with larger radius
×
Premature Wear
Premature Wear
Cause
Cutting speed too high
Infeed depth too small
Highly abrasive material
Inadequate coolant supply
Wrong inclination anvil
Wrong turned dia. prior to threading
Insert is above center line
Remedy
Reduce RPM
Modify flank infeed /increase depth of cut
Use coated grade
Apply coolant
Reselect anvil
Check turned dia.
Check center height
×
Insert Breakage
Insert Breakage
Cause
Wrong turned dia. prior to threading
Wrong Grade
Poor chip control
Incorrect center height
Remedy
Check turned dia.
Use tougher grade
Change to M/B type inserts and use modified flank infeed
Check center height
×
Built-up Edge
Built-up Edge
Cause
Cutting edge too cold
Wrong grade
Inadequate coolant supply
Incorrect cutting speed
Remedy
Increase RPM /increase depth of cut
Use coated grade
Apply coolant
Change cutting speed
×
Vibration
Vibration
Cause
Incorrect workpiece clamping
Incorrect tool setup
Incorrect cutting speed
Incorrect center height
Remedy
Use soft jaws
Check tool overhang / use anti vibration bars
Increase cutting speed
Check center height
×
Poor Surface Finish
Poor Surface Finish
Cause
Wrong cutting speed
Excessive heat in cutting zone
Poor chip control
Inadequate coolant supply
Wrong inclination anvil
Tool overhang too long
Incorrect center height
Remedy
Increase/reduce RPM
Reduce depth of cut
Modify flank infeed
Apply coolant
Reselect anvil
Reduce tool overhang
Check center height
×
Poor Chip Control
Poor Chip Control
Cause
Excessive heat in cutting zone
Wrong grade
Inadequate coolant supply
Wrong turned dia. prior to threading
Incorrect method of infeed
Remedy
Reduce RPM /change depth of cut /check turned dia.
Use coated grade /check turned dia./use M/B type inserts
Apply coolant
Check turned dia.
Modified flank infeed 3-5°
×
Thread Profile is Too Shallow
Thread Profile is Too Shallow
Cause
Incorrect center height
Worn insert
Insert isn’t machining the tread crest
Excessive wear
Remedy
Check center height
Change to new cutting edge sooner
Check the workpiece dia.
Increase radial infeed
×
Broken Nose During First Pass
Broken Nose During First Pass
Cause
Cutting edge too cold
Depth of cut too large
Wrong grade
Wrong turned dia. prior to threading
Incorrect center height
Infeed depth too shallow
Wrong inclination anvil
Tool overhang tool long
Remedy
Increase RPM
Reduce depth of cut/increase number of infeed passes
Use tougher grade
Check turned dia.
Adjust center height
Modify flank infeed
Reselect anvil
Reduce tool overhang
×
Incorrect Thread Profile
Incorrect Thread Profile
Cause
Unsuitable thread profile
Incorrect center height
Incorrect pitch in the program
Remedy
Adjust to correct tool ,anvil and insert
Adjust center height
Change the program
×
Flank Wear
Flank Wear
Cause
High cutting speed
Remedy
Reduce cutting speed
Cause
Chip too thin
Remedy
Increase feed rate and reduce radial passes
Cause
Insufficient coolant
Remedy
Check coolant pressure / flow direction
×
Fracture/Chipping
Fracture/Chipping
Cause
Vibration
Remedy
Check stability
Cause
High load on cutting edge
Remedy
Reduce feed rate
Add radial passes
×
Build-up Edge
Build up Edge
Cause
Cutting speed too low
Remedy
Increase cutting speed
Cause
Insufficient coolant
Remedy
Check coolant pressure / flow direction
×
Thread Surface-Chatter Marks/Vibrations
Thread Surface-Chatter Marks/Vibrations
Cause
Feed rate is too high
Remedy
Reduce feed rate
Cause
Large profile
Remedy
Add passes
Cause
Thread length too long
Remedy
Add radial passes
Reduce overhang
×
Thread Accuracy (GO/NOGO Gauge)
Thread Accuracy (GO/NOGO Gauge)
Cause
Tool deflection
Remedy
Reduce feed rate
Add radial passes
Use ZERO compensation
Cause
CNC program error
Remedy
Check CNC program
×
Insert/Tool Breakage
Insert/Tool Breakage
Cause
High load on the cutting edge
Remedy
Add radial passes
Cause
Unproper cutting conditions
Remedy
Adjust cutting conditions
Cause
Chip evacuation
Remedy
Add sufficient coolant
Cause
CNC program error
Remedy
Check CNC program
×
Tapered Thread
Tapered Thread
Cause
Tool cutting load
Remedy
Add radial passes and/or reduce cutting conditions
Cause
Tool overhang
Remedy
Clamp tool to the minimum overhang length
×
Short Tool Life
Short Tool Life
Cause
Unsuitable cutting conditions
Remedy
Adjust feed/speed
Cause
Vibrations
Remedy
Reduce overhang as short as possible
Check tool and workpiece clamping
×
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