Chip breaking

Chips too short and hard

• Feed too high
• Cutting speed too low
• Unsuitable geometry

• Decrease feed
• Increase cutting speed
• Change geometry to a more open chip breaker

Chip breaking

Chips too long

• Feed too low
• Cutting speed too high
• Unsuitable geometry

• Increase feed
• Decrease cutting speed
• Change geometry to a more closed chip breaker

Tool vibration

• Tool length/coupling size ratio too high

• Use largest possible coupling size
• Use/shorten the dampened boring tool

• Unstable conditions

• Ensure rigid clamping with face contact to spindle
• Use rough boring tool with a two-insert design
• Check that all units in the tool assembly are assembled correctly, with correct torque
• Check machine spindle, workpiece clamping, wear, etc.

• Feed too low

• Increase feed

• Feed too high

• Decrease feed

• Speed too high

• Decrease cutting speed

• Cutting depth too large

• Apply step boring

• Cutting force too high

• Decrease depth of cut
• Use positive inserts
• Use smaller nose radius
• Wiper inserts not recommended for long overhangs or unstable conditions

• Cutting force too low

• Increase depth of cut

Machine power

• Limited machine power

• Make sure the machine can provide the required torque and power for the specific boring application, especially when rough boring
• Decrease cutting data
• Apply step boring

Chip breaking

Chips too short and hard

• Feed too high
• Cutting speed too low
• Unsuitable geometry

• Decrease feed
• Increase cutting speed
• Change geometry to a more open chip breaker

Chip breaking

Chips too long

• Feed too low
• Cutting speed too high
• Unsuitable geometry

• Increase feed
• Decrease cutting speed
• Change geometry to a more closed chip breaker

Tool vibration

• Cutting force too high

• Use largest possible coupling size
• Use a light cutting insert
• Use smaller nose radius
• Use sharp cutting edges, uncoated or with thin coating
• Wiper inserts are not recommended for long overhangs or unstable conditions
• Use a smaller nose radius
• Decrease depth of cut

• Tool length/coupling size ratio too high

• Ensure rigid clamping with face contact to spindle
• Use largest possible coupling size
• Shorten the assembly, if possible
• Use dampened boring tools

• Unstable conditions

• Ensure rigid clamping with face contact to spindle
• Check that all units in the tool assembly are assembled correctly, with correct torque
• Check machine spindle, workpiece clamping, wear, etc.

• Feed too high

• Decrease feed

• Speed too high

• Decrease cutting speed

• Friction instead of clean cutting action

• Increase depth of cut

Machine power

• Limited machine power

• Make sure the machine can provide the required torque and power for the specific boring application, especially when rough boring

• Vibration

• Reduce speed. See above for additional solutions

• Feed marks

• Use a light cutting insert
• Use larger nose radius
• Decrease feed

• Worn insert

• Change cutting edge. For how to avoid specific wear patterns

• Chip scratching surface

• Improve chip breaking