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Problem
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Possible Cause
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Remedy
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Poor Chip Control
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Feed rate too low
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Increase feed rate
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Excessive height variation of inserts
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Preset tool to max .0002" variation of both inserts
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Excessive stock allowance
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Consult cutting data tables
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Width of chip excessive D.O.C.
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Preset tool for stepped cutting method
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Chatter & Vibration
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Excessive SFM
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Reduce SFM, check recommended parameters
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Extreme length to diameter ratio
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Shorton tool to increase stiffness or
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Increase boring bar diameter to larger size or
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Change boring bar to carbide or heavy metal
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Insert radius too big
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Reduce nose radius of insert (duh)
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Unstable workpiece
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Improve fixture and clamping support
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Lead angle on insert holders
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Change to 90 degree insert holders
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Insert Chipping or Breaking
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Wrong Insert
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Change to tougher grade of carbide insert or
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Use larger radius if available
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Severe interruption
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Increase speed, decrease feed
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Chips packing and re-cutting
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Check for boring bar/bore diameter clearance
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Improve chip control, increase feed
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Poor Tool Life
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Wrong Insert
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Change to higher wear resistant grade
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Excessive cutting speed
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Reduce speed
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Insert chipping
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Check stock allowance and feed rate
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Coolant pressure too low
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Increase through tool coolant pressure
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Adjust coolant ports of head if available
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Chips Not Evacuating
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Boring bar diameter is too large
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Reduce to smaller head and extended range holder
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Excessive stock allowance
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Re-set tool for stepped cutting
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Inadequate space below bore
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Elevate workpiece from table more
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Insufficient Machine Power
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Excessive feed rate
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Reduce feed; minimum 25% of insert radius
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Stock allowance excessive
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Reset tool for stepped cutting method
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Low machine torque
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RPM in area of low spindle torque; increase speed
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RPM in area of gear change; adjust RPM
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Change insert to higher rake angle
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Reduce depth of cut
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Excessive Exit Burr
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Excessive feed rate
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Reduce feed rate
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Cutting forces too high
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Reduce depth of cut
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Reduce insert radius
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