Техническая информация Sumitomo - страница 18

Tool Failure and Remedies

■ Troubleshooting for Drilling

Failure Cause Basic Remedies Remedy Examples

• Inappropriate cutting
• Use higher cutting speeds.
• Refer to the upper limit of the recommended conditions listed the Igetalloy Cutting Tools Catalogue.

Excessive Wear on

Cutting Edge conditions. Increase feed rates. Refer to the upper limit of the recommended conditions listed the Igetalloy Cutting Tools Catalogue.

• Reduce pressure if using internal coolant.
• 1.5 MPa or below (external coolant if hole depth is L/D = 2 or less).
• Unsuitable cutting fluid.
• Use cutting fluid with more lubricity.
• Use JIS A1 grade No. 1 or its equivalent.
• Reduce feed rate at entry point.
• f=0.08 to 0.12mm/rev

Chisel Point Off-center starts. Chipping Pre-processing to ensure flat contact surface. Use endmill to produce flat surface.

• Equipment and/or work
• Change cutting conditions to reduce resistance.
• Increase v and decrease f (reduce thrust).

c material lacks rigidity. Improve work material clamp rigidity.

• Cutting edge is too
• Increase size of chisel width.
• Set chisel width from 0.1 to 0.2 mm.

weak. Increase amount of honing on cutting edge. Make thinning section of central area 1.5x current width.

• Inappropriate drilling
• Decrease the cutting speed.
• Refer to the lower limit of recommended conditions listed in the Igetalloy Cutting Tools Catalogue.

Chipping On

• Equipment and/or work material lacks rigidity.
• Improve work material clamp rigidity.
• Cutting edge is too
• Increase amount of honing on cutting edge.
• Make peripheral cutting edge 1.5x current width.

weak. Reduce the amount of front flank angle. Reduce the amount of front flank angle by 2° to 3°.

• Peripheral cutting edge starts cutting first
• Increase margin width (W margin).
• Increase margin width by 2 to 3x current width.
• Cutting interrupted
• Reduce feed rate.
• Refer to the lower limit of recommended conditions listed in the Igetalloy Cutting Tools Catalogue.

when drilling through Increase amount of honing on cutting edge. Make peripheral cutting edge 1.5x current width. workpiece. Reduce the amount of front flank angle. Reduce the amount of front flank angle by 2° to 3°.

• Inappropriate drilling conditions.
• Decrease the cutting speed.
• Refer to the lower limit of recommended conditions listed in the Igetalloy Cutting Tools Catalogue.

Margin Wear

• Unsuitable cutting
• Use cutting fluid with more lubricity.
• Use JIS A1 grade No. 1 or its equivalent.

fluid. Increase coolant supply. If using external coolant, change to internal coolant supply.

• Latent margin wear.
• Early regrind to ensure adequate back taper.
• Regrind margin damage to 1 mm or less.
• Increase amount of back taper.
• Make back taper 0.5/100.
• Unsuitable tool design.
• Reduce margin width.
• Decrease margin width to two-thirds of current width.
• Use optimal cutting conditions and tools.
• Refer to the table of recommended conditions in the Igetalloy Cutting Tools Catalogue.

Drill Breakage Chip build-up.

• Increase coolant supply.
• If using external coolant, change to internal coolant supply.
• Replace collet chuck if damaged.
• Collet clamp lacks strength.
• Use collet with strong grip force.
• Use collet holder one size bigger.
• Equipment and/or work material lacks rigidity.
• Improve work material clamp rigidity.
• Reduce feed rate at entry point.
• f=0.08 to 0.12mm/rev

Oversized Holes

• Off-center starts.
• Decrease the cutting speed.
• Refer to the lower limit of recommended conditions listed in the Igetalloy Cutting Tools Catalogue.
• Pre-processing to ensure flat contact surface.
• Use endmill to produce flat surface.
• Use optimal drill type for hole depth.
• Refer to the Igetalloy Cutting Tools Catalogue.
• Drill bit lacks rigidity.
• Improve overall rigidity of drill.
• Large web with comparatively small flute.
• Improve drill clamp precision.
• Replace collet chuck if damaged.
• Drill bit has run-out
• Improve drill clamp rigidity.
• Use collet holder one size bigger.
• Equipment and/or work material lacks rigidity.
• Improve work material clamp rigidity.
• Inappropriate cutting
• Increase cutting speeds.
• Refer to the upper limit of the recommended conditions listed the Igetalloy Cutting Tools Catalogue.

Poor Surface Finish

conditions. Reduce feed rate. Refer to the lower limit of recommended conditions listed in the Igetalloy Cutting Tools Catalogue.

• Unsuitable cutting fluid.
• Use cutting fluid with more lubricity.
• Use JIS A1 grade No. 1 or its equivalent.
• Off-center starts.
• Increase feed rates.
• Refer to the upper limit of the recommended conditions listed the Igetalloy Cutting Tools Catalogue.

Holes Are Not

• Equipment and/or work
• Improve work material clamp rigidity.

material lacks rigidity. Select a double margin tool. Refer to the Igetalloy Cutting Tools Catalogue.

• Inappropriate drilling
• Increase cutting speeds.
• Refer to the upper limit of the recommended conditions listed the Igetalloy Cutting Tools Catalogue.

Packing Of Chips

conditions. Increase feed rates. Refer to the upper limit of the recommended conditions listed the Igetalloy Cutting Tools Catalogue.

• Poor chip evacuation.
• Increase the amount or pressure of coolant applied if using internal coolant.
• Inappropriate drilling
• Increase feed rates.
• Refer to the upper limit of the recommended conditions listed the Igetalloy Cutting Tools Catalogue.

Long Stringy Chips

conditions. Increase cutting speeds. Refer to the upper limit of the recommended conditions listed the Igetalloy Cutting Tools Catalogue.

• Cooling effect is too strong.
• Reduce pressure if using internal coolant.
• Keep pressure 1.5 MPa or lower if using internal coolant.
• Dull cutting edge.
• Reduce amount of edge honing.
• Reduce to around two-thirds of current width.