Troubleshooting Turning

Failure Mechanism Analysis and Corrective Actions

Turning problem - edge wear

Problem:

Edge Wear

Corrective Action:

  • Increase feed rate
  • Reduce speed (sfm)
  • Use more wear-resistant grade
  • Apply coated grade
Turning problem - chipping

Problem:

Chipping

Corrective Action:

  • Utilize stronger grade
  • Consider edge preparation
  • Check rigidity of system
  • Increase lead angle
Turning problem - heat deformation

Problem:

Heat Deformation

Corrective Action:

  • Reduce speed
  • Reduce feed
  • Reduce depth-of-cut (doc)
  • Use grade with higher hot hardness
Turning problem - depth-of-cut notching

Problem:

Depth-of-Cut Notching

Corrective Action:

  • Change lead angle
  • Consider edge preparation
  • Apply different grade
Turning problem - thermal cracking

Problem:

Thermal Cracking

Corrective Action:

  • Properly apply coolant
  • Reduce speed
  • Reduce feed
  • Apply coated grades
Turning problem - built up edge

Problem:

Built-Up Edge

Corrective Action:

  • Increase speed (sfm)
  • Increase feed rate
  • Apply coated grades or cermets
  • Utilize coolant
  • Edge prep (smaller hone)  
Turning problem - crater

Problem:

Crater

Corrective Action:

  • Reduce feed rate
  • Reduce speed (sfm)
  • Apply coated grades or cermets
  • Utilize coolant
Turning problem - catastrophic breakage

Problem:

Catastrophic Breakage

Corrective Action:

  • Utilize stronger insert geometry or grade
  • Reduce feed rate
  • Redce depth-of-cut (doc)
  • Check rigidity of system
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