Troubleshooting General notes All the eutting rate recommendations specified in this ea- chine epindle. Our recommended cutting rates must be talogue are standard values valid exclusively for new tools reduced ifthe conditions deviate, The values may also be or tools re-ground to Gubving specifications. Pre-requisites adjusted to intluence Surface finish quality, machining rate {are stable machines, optimal cooling, optimal tool clam- or tool ie. ping and maximum concentrcity of the tool and the ma- 1. Workpiece clamping ms Loss of too! life or tool breakage through unstable clamping > improve workpiece clamping Alternative: > reduce feed > reduce cutting width or depth = 2.Tool clamping Loss of too! life or tool breakage through unstable, worn or too smalllongitin too! holder > apply new or larger tool holder or holder with inereased clam: ping free and ineressed coneentvicty ‘Aerative: > reduce cutting rates > reduce clamping langth > apply tool with smaller diamotor > check clamping serews for wear 2. Surface finish quality Excessive peakto-vallay height a/Rz atthe tool Surface finish through excessive feed and food rates ot vibrations > improve workpiece clamping and tool clamping eee points 1 and 2) Aterative: > reduce feed and feed rate fz > increase cuting speed 4.Vibrations High tool wear, insutficient workpiece Surface finish quality and insut- ficient dimensional accuracy through vibration eonnacaL > improve workoiece and tool clamping (see points 1 and 2) > increase tooth feed, because the chip centre thickness is too small > modify sped > modify miling strategy, ie. select alternative cutting distribution > change too! selection, ie. reduce no. of testh or spir GUHRING | 13Troubleshooting 5. Chip congestion/cooting Significant reduction in too lif, crumbling on cutting tis, ‘edge build-up or conglutination of flutes through insu cient chip evacuation > select milling cutters with internal cooling Alternative: > peripheral cooling via GM 300 chuck > increase volume flow > agjust coolant flow > apply compressed air cooling (according to tool and material), > reduce feed rate > modify cutting distribution 6.Pecking when drilling Significant reduction in tool life a well as crumbling of cutting lips through insufficient chip evacuation and th: mal stresses > select miling cutter with internal cooling with driling depths > 0.5 x D pecking in stages Alternative: > peripheral cooling via GM 300 chuck > increase volume flow > agjust coolant flow > reduce feed rate ‘7:Thermal influence on materials Through welding or torch cutting, the material characto- tistics atthe parting line do not correspond with the spe cified material class > reduce cutting rates > select tool for materials with a highs tensile strangth 8. Entry in hardened materials For entering materials over 44 HRC, reduce the food rate vf (mm/min in aczordance with the illustration on the right, 114 | GUHRING sare: stotmitng Rovehing pithing FEEDS a SPEEDS.sons eso Troubleshooting 2: Lose nto! fe wth ntarptedctting Significant toss into! if trough interupted euting SO {especially with milling angles of 90°) > madify cutting distribution > reduce feed rate for entry and exit > reduce approach angle 10, Feed rate adjustment: Modifying the cutting width > when modifying the cutting width WOC, the feed rate must be reduced in accardance with the illustration on the right > cutting epeed or revolutions remain unchanged > double reduction applies when also modifying the cut- ting depth DOC! woc=1xD IPT=25 % WoC = 0.25 xD IPT= 100 % 11. Feed rate adjustment: Medifying the cutting depth > when modifying the cutting depth DOG, the feed rate must be reduced in accordance with the illustration fon the right > cutting speed or revolutions remain unchanged up to + cutting depths of 3x D, must only be adapted over 3x D > double reduction applies when also modifying the cut- ting width ae! Doc=1xp PT= 100% > reduce feed rate vs (mm/min.) > additional pecking for drilling depths > 0.5 x D or tran: sition to radial machining ‘Attention: Danger of breakage through abrupt load increase Dating tqve pring Pe Oblique plunging up to 15° (preferred): J > reduction in feed rate vj (mm/min,) not required xd rate IPT in accordance withthe illustration 4 fon the right za Z r 2 Helical plunging: > for helical plunging on a milling cycle, we recommend gor ap aes feed of 0.1 100.2 per eycle PT-70% IPT=100% PT-30% —IPT-15% > reduce food rate vs (mm/min. in accordance with the illustration on the right > select proferred hole diameter 18 xD GUHRING | 15Troubleshooting 18. Copy milling For cutting depths DOC<0.5xD, the engaged effective diameter Dei must be spindle not engaged, the effective diamot plied to calculate the speed. With the alculated according to the illustration blow. To increase tool lif, wa rocommend machining with tited spindle. The tit angle must be taken into account when calculating the offective diameter Dat , CAD) 0mn=2.-005-0008 Ce oun -sfp aes (Range 00¢ = 05-100 mm) bi osmn) Curing depth DOC Modifying the cutting width WOC results in improved Surface finish quality of the workpiece {reduced poak:to-valley height) Reh Nousas Sania. Wor 16 | GUHRING