| Plastic Deformation | Cause • Excessive heat in cutting zone • Wrong carbide grade • Inadequate coolant supply • Depth of cut too large • Cutting speed too high • Nose radius too small | Solution • 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 | • 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 | • Reduce RPM • Modify flank infeed / Increase depth of cut • Use coated grade • Apply coolant • Reselect anvil • Check turned dia. • Check center height |
| Insert Breakage | • Wrong turned dia. prior to threading • Wrong grade • Poor chip control • Incorrect center height | • Check turned dia. • Use tougher grade • Change to M-Type / B-Type inserts and use modified flank infeed • Check center height |
| Build Up Edge | • Cutting edge too cold • Wrong grade • Inadequate coolant supply • Incorrect cutting speed | • Increase RPM / Increase depth of cut • Use coated grade • Apply coolant • Increase cutting speed |
| Vibration | • Incorrect workpiece clamping • Incorrect tool setup • Incorrect cutting speed • Incorrect center height | • Use soft jaws • Check tool overhang / Use anti-vibration bars • Increase cutting speed • Check center height |
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