Trouble shooting PCBN milling Problem Flank wear Crater wear Notch wear Edge chipping Edge flaking (continuous cut) Edge flaking (interrupted cut) Edge breakage Insert breakage Cause Not correct edge temperature Suggested action(s) Increase cutting speed Increase feed rate Increase depth of cut Check cutting tool centre height Check the ferrite content Not correct edge temperature Decrease cutting speed Decrease feed rate Reduce chamfer angle Use E edge preparation Use coated insert Use coolant (only in continuous cut) Not correct edge temperature Too high cutting forces Increase cutting speed Decrease feed rate Increase insert approach angle (preferably round inserts) Vary the depth of cut Use inserts with chamfered cutting edges Too high cutting forces Use inserts with chamfered cutting edges Increase system rigidity For interrupted cuts, chamfer the tool entry/exit slots and holes Vary the cutting speed to eliminate vibrations Too high cutting forces Increase cutting speed Reduce feed rate Use chamfered and honed cutting edges Check cutting tool center height Reduce insert approach angle Too high cutting forces Do not use coolant Use chamfered and honed cutting edges Reduce feed rate Increase cutting speed Check cutting tool centre height Reduce insert approach angle Too high cutting forces Reduce depth of cut Reduce cutting speed Increase nose radius Use chamfered and honed inserts Check cutting tool center height Too high cutting forces Check insert seating Check insert shim and insert clamp Check cutting tool centre height 732
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