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Problem
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Solution
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Burr
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Assure tool center height
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Use sharp tool (index more often)
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Use positive rake PVD coated insert
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Use correct grade for workpiece material
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Use correct geormetry (ie. positive rake for workhardening material)
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Chamfer before grooving
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Change tool path
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Poor Surface Finish
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Increase speed
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Use sharp tool (index more often)
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Dwell tool in bottom 1 - 3 revolutions (max)
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Use proper chip control geometry
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Increase coolant flow/concentration
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Assure proper setup (overhang, shank size)
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Use correct geormetry (ie. positive rake for workhardening material)
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Groove Bottom Not Flat
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Use sharp tool (index more often)
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Dwell tool in bottom 1 - 3 revolutions (max)
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Reduce tool overhang (icnrease rigidity)
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Assure correct tool alignment
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Reduce feed rate at groove bottom
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Use a wider insert
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Assure tool center height
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Poor Chip Control
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Use chip control geometry insert
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Use sharp tool (index more often)
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Increase coolant concentration
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Adjust feed rate (usually increase first)
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Chatter
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Reduce tool and workpiece overhang
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Adjust speed (usually increase first)
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Adjust feed (usually increase first)
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Assure center height
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Insert Chipping
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Use correct grade for workpiece material
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Increase speed
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Reduce feed
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Use a stronger grade
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Increase tool and setup rigidity
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Built-Up Edge
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Use positive PVD coated insert
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Increase speed
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Reduce feed
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Increase coolant flow/concentration
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Use cermets
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For aluminum, use polycrystalline diamond insert (PCD)
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Side Walls Not Straight
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Check tool alignment for square
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Use correct insert hand
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Reduce workpiece and tool overhang
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Use sharp insert (index more often)
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