| | | Insert Grade Selection | | | | Cutt | ing Conditions | Style of | and the | T | Desi ool | gn | Ma Instal | chi lati | n o | e n | and of Tool |
| Trouble | Solutions Factors | Coated Tool | Cutting Speed U Do | p w | Feed Rate | Depth of Cut n | Cutting Fluids Decrease Pick Feed Rate Down Cut Air Blow Increase Coolant Quantity Do Not Use Water- soluble Cutting Fluid Determine Dry or Wet Cutting | Helix Angle Number of Flutes Up Dow | Concavity Angle of End Cutting Edge n | Tool Diameter | Improve End Mill Rigidity | Wider Chip Pocket | Shorten Tool Overhang Tool Installation Accuracy | Spindle Collet Run-out Accuracy | | Collet Inspection and Exchange | Increase Chuck Clamping Power Machine Stability, Rigidity |
| | Non-coated insert is used | a | | | | | | | | | | | | | | | |
| Large wear t th ihl | Not enough flutes | | | | | | | a | | | | | | | | | |
| a e perpera cutting edge | Improper cutting conditions | | a | | | | a | | | | | | | | | | |
| | Up cut milling | | | | | | Down Cut | | | | | | | | | | |
| Life | | Improper cutting conditions | | | | | | | | | | | | | | | | |
| ool | Chipping | Fragile cutting edge fi | | | | | | | | | | a | | | | | | |
| rt T | | Insufficient clamping force | | | | | | | | | | | | | | | a | a |
| Sho | | Poor clamping rigidity | | | | | | | | | | | | a a | a | | a | a a |
| | Improper cutting conditions | | | | | a | | | | | | | | | | | |
| Breakage durin | Poor end mill rigidity | | | | | | | | | a | a | | | | | | |
| g cutting | Overhang longer than necessary | | | | | a | | | | | | | a | | | | |
| | Chip packing | | | | | | a | | | | | a | | | | | |
| Vibration during | Improper cutting conditions Poor end mill rigidity | | a | | a | | | a a | | a | a | | | | | | |
| cutting | Poor clamping rigidity | | | | | | | | | | | | a a | a | | a | a a |
| | Lare cuttin | | | | | | | | | | | | | | | | |
| | g g d | a | | | | | | | | | | | | | | | |
| nish | Poor wall surface | ege wear Improper cutting conditions | | a | | | a | | | | | | | | | | | |
| e Fi | roughness | Chip jamming | | | | | | a a a Wet | | | | | | | | | | |
| rfac | Poor bottom surface | The end cutting edge does not have a concave angle | | | | a | a | | | a | | | | | | | | |
| Su | roughness | Large pick feed | | | | | | a | | | | | | | | | | |
| oor | | Large cutting edge wear | a | | | | | | | | | | | | | | | |
| P | Out of vertical | Improper cutting conditions | | | | a | a | | | | | | | | | | | |
| | Poor end mill rigidity | | | | | | | a a | | a | a | | | | | | |
| Poor surface finish | Improper cutting conditions | | a | | a | a | | | | | | | | | | | |
| i accuracy | Poor clamping rigidity | | | | | | | | | | | | a a | a | | a | a a |
| Burrs | Burr, work material | Improper cutting conditions | | | | a | a | | | | | | | | | | | |
| ing / | chipping | Large helix angle | | | | | | | a | | | | | | | | | |
| Chipp | Quick burr | Notch wear occurs | a | | | | | | | | | | | | | | | |
| Burr / | formation | Improper cutting conditions | | a | | a | | | | | | | | | | | | |
| ontrol | | Metal removal too large | | | | a | a | | | | | | | | | | | |
| Chip C | Chip packing | Lack of flute chip space | | | | | | | a | | | | a | | | | | |