Abrasion-Rapid Tool Wear
Speeds & Feeds
Coolant problem

Cratering-Edge Pitting
Feeds & Speeds
Coolant problem
Hold down
Tool geometry

BUE-Built Up Edge
Coolant problem
Tool geometry
Flute & Edge finish
Feeds & Speeds

Chip Welding
Feeds & Speeds
Coolant problem

Chip Packing
Flute space, helix
Coolant problem

Poor Finish
Dull tool
Incorrect feed and speeds
Wrong tool being used
Run out

Inaccurate Machining
Dull tool
Machine misalignment

Scalloping
Tool balance
Work piece deflection
Tool & Tool holder not concentric

Inaccurate Slot Position
Milling to much material

Sloping Slot Sides
Wrong type of tool
Feed rates

Chatter
Feeds & Speeds
Hold down
Deflection
Tool geometry
Run out

Rubbing
Dull tool
Deflection
Feed

Spindle Stall
Horse power
Tool geometry
Milling style

Abrasion-Rapid Tool Wear-Solution
Make sure Speeds & Feeds are correct for application
Make sure coolant mix ratio is correct

Cratering-Edge Pitting-Solution
Bolster hold down-make sure its rigid
Make sure coolant mix ratio is correct
Decrease speed
Reduce load per tooth

BUE-Built Up Edge-Solution
Make sure coolant mix ratio is correct
Resharpen cutting edges
Increase chip load per tooth
Increase speed
Increase clearance angle

Chip Welding-Solution
Reduce Speeds & Feeds
Make sure coolant mix ratio is correct

Chip Packing-Solution
Use tool with less flutes
Increase coolant flow

Poor Finish-Solution
Sharpen tool
Replace tool
Reduce load per tooth
Use tool with more teeth
Check tool holder and/or play in spindle

Inaccurate Machining-Solution
Sharpen tool
Replace tool
Check table alignment
Check ball screws, spindle bearings, and other moving parts

Scalloping-Solution
Tool may be out of round
Replace tool
Reduce feed rate
Make sure holder and spindle are true
Bolster hold down-make sure its rigid

Inaccurate Slot Position-Solution
Use roughing and finishing operation
Reduce feed rate

Sloping Slot Sides-Solution
Change from helical to straight flute tool
Use roughing and finishing operation

Chatter-Solution
Increase feed per tooth
Bolster hold down-make sure its rigid
Tool should be held with minimum stick out
Increase chip load per tooth
Make sure holder and spindle are true

Rubbing-Solution
Sharpen tool
Replace tool
Use larger diameter tool if possible
Reduce feed rate

Spindle Stall-Solution
Recalculate horsepower requirements
Reduce area of work-tool contact
Reduce load per tooth
Increase rake or clearance angle on tool
If conventional milling, try climb milling