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Troubleshooting Turning
Failure Mechanism Analysis and Corrective Actions
Problem:
Edge Wear
Corrective Action:
- Increase feed rate
- Reduce speed (sfm)
- Use more wear-resistant grade
- Apply coated grade
Problem:
Chipping
Corrective Action:
- Utilize stronger grade
- Consider edge preparation
- Check rigidity of system
- Increase lead angle
Problem:
Heat Deformation
Corrective Action:
- Reduce speed
- Reduce feed
- Reduce depth-of-cut (doc)
- Use grade with higher hot hardness
Problem:
Depth-of-Cut Notching
Corrective Action:
- Change lead angle
- Consider edge preparation
- Apply different grade
Problem:
Thermal Cracking
Corrective Action:
- Properly apply coolant
- Reduce speed
- Reduce feed
- Apply coated grades
Problem:
Built-Up Edge
Corrective Action:
- Increase speed (sfm)
- Increase feed rate
- Apply coated grades or cermets
- Utilize coolant
- Edge prep (smaller hone)
Problem:
Crater
Corrective Action:
- Reduce feed rate
- Reduce speed (sfm)
- Apply coated grades or cermets
- Utilize coolant
Problem:
Catastrophic Breakage
Corrective Action:
- Utilize stronger insert geometry or grade
- Reduce feed rate
- Redce depth-of-cut (doc)
- Check rigidity of system