84
7.9 Failures in turning
Table 7.7 Failures and their causes in turning
7.9.1 Tool failures
Consequence for the tool Cause of the failure
Tool top chipping (in the Too small wedge angle, results
case of cemented carbide in accumulation of heat
tools)
Tool vibrations resulting from
too long clamping
Cemented carbide cut- Vibrations, for example because
ting edge is chipping of too much backlash in the
longitudinal guideways or in the
main spindle bearing
Vibrations, for example due to
machine overload
Large flank face wear Tool orthogonal clearance too
small tool presses
Tool tip is above the centre of
workpiece axis
thus efficient tool orthogonal
clearance is too small
Tool tip in the case of Cutting speed too high creates
high speed tools fuses too much heat
off Too high sectional area of chip
Consequence: too great forces
too high heat
Strong crater wear Too high cutting speed
Tool life too short Too high cutting speed
7.9.2 Workpiece failures
Consequence for the Cause of the failure
workpiece
workpiece becomes Workpiece deflects
noncircular wrong tool cutting-edge angle
Centre in main spindle wob-
bles (runs out)
Workpiece inexactly centred
Longitudinal guidances or
main spindle bearing has too
much backlash
Clamping force deforms
tube-shaped workpiece
7 Turning
Remedy
Increase wedge angle or
affix chamfers to rake
angle and flank faces
Clamp at shorter length or
select greater shank cross
section
Readjust backlash in guid-
ances or bearings
Use another machine with
greater stiffness
Increase tool orthogonal
clearance
Correct tool height
adjustment
Diminish vc
Diminish chip cross
section,above all, reduce
depth of cut
Diminish vc
Diminish vc
Remedy
Increase tool cutting-edge
angle
Check taper in main spindle
and remove dust
Recentre
Readjust guidances or main
spindle bearing
Reduce clamping force
Diminish chip cross section
7.10 Reference tables 85

Consequence for the tool Cause of the failure Remedy

Workpiece surface Vibrations, for example Readjust guidances
becomes wavy because guidance backlash is
too great
Incorrect tool clamping Clamp tool shorter
(vibrations)
Too high metal removal rate Diminish chip cross section
results in vibrations in the or change v
machine
Workpiece deflects Stationary steadyrest incor- Readjust steadyrest jaws
rectly adjusted
Surface roughness too Too high feed and Diminish feed
great obvious grooves too small peak radius Increase peak radius
on the turning tool
Bright stripes on Bright braking due to fused Diminish v
workpiece off tip on the high speed steel
turning tool
Workpiece becomes Centres dont align Readjust tailstock sidewise
conical during turning
between centres

7.10 Reference tables

The recommended values for v15 in the Tables 7.8 and 7.9 are applicable for depths
of cut from ap = 1 to 4 mm. If depth of cut is greater than 4 mm (up to about 10 mm),
it is necessary to reduce these values by about 8 %. Allowable cutting speeds are
valid for a tool life T = 15 min.
These cutting speeds can be transformed to allow for a tool life of T = 8 min, T = 30
min, T = 60 min with the following factors.

v8 = v15 1,25
v30 = v15 0,8
v60 = v15 0,6
Currently, because of the short tool change times for clamp-type tool holders, we
predominantly work with tool life values from:
T= 15 to 30 min.
In many cases, though not exclusively, cam-controlled automatic lathes work with
tool life values from T = 240 to 480 min. Numerically-controlled lathes with short
reset times operate with v15 to v60 values.
Depending on the work required for reset or setup time and the number of work-
pieces to be machined, cutting speeds and thus the tool life values are adapted to the
production conditions.
9.8 Failures in drilling 139

Helical flutes right-handed helix

direct the chips in the direction opposite to that of the feed, backward in the shank
direction. For this reason, right-handed helix taps are used for blind holes. The nor-
mal helix angle is around 15.
Taps with right-handed helical flutes, in which the flutes are particularly wide-
spaced and the helix angle is large (35), are used for deep blind holes. The taps
rake angles range from 3 to 20.
Table 9.12 Tap rake angle
Grey cast Steel Light metal
Material
iron Rm 500 N/mm 2
Rm > 500 N/mm2 (long-chip)
rake angle 3 15 810 20

9.8 Failures in drilling

Table 9.13 Failures and corresponding reasons in drilling

9.8.1 Tool failures

Consequences for the tool Reason for the failure
Drill hooks in and breaks Point angle too small
Tang damaged or broken off Drill cone, or cone in
the drilling machine
contaminated or damaged
Drill fracture Drill core too weak
Excessive land wear Unilateral grinding of
the bit
Fracture of the drill Feed too high
flutes clogged
Excessive land wear Cutting speed too high
poor cooling
Premature dulling of the Cutting speed too high
drill poor cooling
Drill point with temper Cutting speed too high
colour feed at deep holes too
high poor cooling
Remedy
Select greater point angle
Repair cone
Use more stable drill
Grind bit centrically
Take smaller feed frequently
remove chips from flutes
Diminish cutting speed
improve cooling
Diminish cutting speed
enhance cooling
Diminish cutting speed reduce
feed enhance cooling

9.8.2 Workpiece failures

Failure in the hole Reason for the failure Remedy
Collars at the holes upper Drill was dull Sharpen tool
side, burr formation at the
lower side burr formation
Wall of the hole very rough Drill was dull Sharpen tool
Hole becomes noncircular Drill has poor guidance Use drill with centre point
in thin-walled workpieces or increase point angle
and sheet metal
11.8 Failures during milling 213

Consequently, the HSS- ES qualities are only used for mills whose diameters are
greater than 20 mm.

Table 11.6 HSS- ES qualities

Material-No. EN 96
1.3202 HS 12-1-4-5
1.3207 HS 10-4-3-10

High speed tools are frequently coated with hard materials (TiC, TiN) to improve
tool life travel.

11.7.8.2 Cemented carbide

For roughing operations, milling cutters with inserted cemented carbide cutting
edges (indexable inserts) are predominantly used.
End mill cutters are generally totally made of cemented carbide, with/ without hard
material coating (TiC, TiN) , characterised by increased tool life travel.

11.8 Failures during milling

Table 11.7
Consequence for the tool
Tool life too short (tools
made of high speed steels)
Cutting edges on the mill
break off
Milling cutters (plain milling Faces of the cutter arbour
cutters) are not parallel to the rings and the locknut are
milling spindle axis
Milling cutter jams on the
cutting edge back (crest)
(plain milling cutter, end mill
cutter)
Reason for the fault Remedy
Cutting speed too high Reduce v
Rake angle too small Check angles
small tool orthogonal
clearance
Feed sz per Diminish feed sz
milling cutter edge too
large
Chip space between the Use tool with other pitch or
cutting edges too small other tool type
Tool climbs during Remove spindle backlash in
down milling the milling machine table
Exchange locknut and
cutter arbour rings
not orthogonal to axis
Tool orthogonal clearance Increase tool orthogonal
too small clearance
214 11 Milling

Table 11.7 (continued)

Consequence for the tool
Insufficient tool life of cutter
heads (cemented carbide
tips)
Indexable inserts made of
cemented carbide break off
on the cutter head
Insufficient surface quality
Surface has equidistant
indentations
Reason for the fault
Incorrect angles on the tool
Cutter head runs out
Chosen cemented carbide
sort too brittle
Indexable inserts not cor-
rectly clamped or bearing
surfaces not plane
Cutting speed too low
Feed per cutting edge too
high
Milling cutter chatters
(due to vibrations)
Cutting forces too high
Insufficient workpiece
clamping
Milling cutter (plain mill-
ing cutter, disk milling cut-
ter or end mill) runs out
Remedy
Grind indexable insert
so that only the chamfers
have a negative rake angle,
whereas the major cutting
edge has a positive rake
angle
Check centre for mounting
Use tougher cemented
carbide
Check chucking system on
the cutter head crest
Increase v
Diminish feed
Reinforce milling-cutter
arbour
Decrease sectional area of
chip or increase rake angle
Check clamping
Check milling-cutter arbour
and clamping element or
milling cutter shank

11.9 Reference tables

Table 11.8 Diameter and tooth numbers for plain milling cutters made of high speed steel
Type Milling cutter
diameter
in mm
n Milling cutter m 10 20 30 40 50 63 80 100 125 160 200
Plain milling cutter DIN 4 4 5 7 8 10 12
884
Shell end mill DIN 841 6 6 7 8 10 12 14
Side and face milling 12 14 14 14 16 18 20
N
cutter DIN 885A
End mill cutter DIN 844 4 4 6 6 8 10
Slotting end mill DIN 2 2 2 2
326D
282 13 Grinding

13.8 Failures during grinding

13.8.1 Parameters influencing the grinding procedure
An optimal grinding result may only be expected if the grinding tool and the condi-
tions (peripheral speed, feed values, infeed) are correctly aligned for the workpiece.
The following Table 13.15 shows the extent to which an alteration of the individual
factors affects the grinding result.

Table 13.15 Parameters influencing grinding and their effects on the grinding result
Alteration Effects on the grinding result
Grinding wheel
Grain size Coarser Higher metal removal rate.
Peak-to-valley height on workpiece increases.
Finer Lower metal removal rate.
Peak-to-valley height on workpiece decreases.
Wheel appears harder and has higher form stability.
Hardness Harder Metal removal rate decreases.
Dull grains break off later or not at all.
Increased heating of the workpiece
(grinding cracks, structural change).
Softer Abrasive grains break off earlier.
Wheel wear increases.
Peak-to-valley height on workpiece increased.
Defects of form increase.
Structure Denser Wheel is harder.
Wheel has higher form stability.
Decreased peak-to-valley height on workpiece.
More open Wheel is softer.
Wheel grinds at lower temperature.
Increased peak-to-valley height on workpiece.
Wheel peripheral speed
Higher Wheel is harder.
Decreased peak-to-valley height on workpiece.
Lower Wheel is softer.
Workpiece speed
Higher Wheel is softer.
Alteration Effect on grinding result
Workpiece form
Small contact zone between wheel Harder wheel required so that abrasive grain does
and workpiece (for example exter- not break off too early.
nal cylindrical grinding)
Large contact zone between wheel Use softer or more open-porous wheel to get close to
and workpiece (for example, in the range of self-sharpening and to limit heating
flat grinding with cup wheel)
Interruptions in Wheel is softer.
the workpiece surface
(excerpt from the records of the Elbe-Schleifmittelwerke)
13.9 Reference tables 283

13.8.2 Table of failures

Table 13.16 Failures during grinding
Effects on the workpiece
Grinding cracks
Scorch marks
soft zones or
distortion on the workpiece
Feed markings
(in cylindrical grinding
helix lines on surface)
Chatter marks
Particles coming off wheel
Grinding grooves
Failure reason Remedy
Wheel too hard Softer grinding wheel
infeed too high lower infeed
cutting speed too high diminish v
insufficient cooling better cooling
Wheel too hard Redress
Wheel incorrectly dressed,
one-sided wheel contact Use softer grinding wheel
Vibrations Softer grinding wheel
Wheel too hard rebalance
or incorrectly balanced check workpiece
workpiece incorrectly mounted mounting
Grains come off the wheel and Improve coolant cleaning
get into the coolant cycle Check grinding wheel
Wheel too rough Use smaller grain size
Sparking out time too short longer sparking out

13.9 Reference tables

Table 13.1 Accuracy values and allowances during grinding
(see Chapter 13.4 page 245).
Table 13.14 Abrasive, grain size, hardness and structure of the grinding wheels
(see Chapter 13.7.4, page 263)

Table 13.17 Feed values during grinding

Cylindrical grinding with Flat grinding
longitudinal feed (peripheral grinding)
Kind of machining
Feed in longitudinal direction Lateral feed
f in mm/revolution f in mm/stroke
2 3 2 4
Roughing B bis B B bis B
3 4 3 5

1 1 1 2
Finishing B bis B B bis B
4 2 2 3
Precision machining 2,0 mm
B in mm grinding wheel width