Turning and peeling problems - what are the potential solutions?

Troubleshooting guide for turning

↑ raise, increase, large influence

⇧ raise, increase, small influence

↓ avoid, reduce, large influence

⇩ avoid, reduce, small influence

≈ check, optimise

◾ use

Type of wear/workpiece problems
Flank wear Crater wear Notch wear Cracks at right angles to the cutting edge Chipping Solution, measures
      Cutting speed vc
Feed f
    Depth of cut ap
    Chamfer angle 35°, heavily interrupted cut
    Chamfer angle 25°, continuous, slightly interrupted cut
    Chamfer angle 15°, continuous, slightly interrupted cut
      Corner radius
  Rounding
        Tool clamping
        Workpiece clamping
        Overhang
      Tip height
  Cooling lubricant

↑ raise, increase, large influence

⇧ raise, increase, small influence

↓ avoid, reduce, large influence

⇩ avoid, reduce, small influence

≈ check, optimise

◾ use

Type of wear/workpiece problems
Insert breakage Chipping on the surface Surface quality Vibration Burr formation Solution, measures
    Cutting speed vc
    Feed f
        Depth of cut ap
  Chamfer angle 35°, heavily interrupted cut
  Chamfer angle 25°, continuous, slightly interrupted cut
  Chamfer angle 15°, continuous, slightly interrupted cut
  Corner radius
Rounding
  Tool clamping
  Workpiece clamping
      Overhang
  Tip height
      Cooling lubricant

Troubleshooting guide for bar peeling

Problem Possible causes Solution
Bar unrounded Inserts do not sit on the same circumference Readjust holder, check insert tolerance, use ground inserts if necessary
  Bar is not inserted centrally in relation to the peeling head Check position of the guide rollers
  Widely varying raw material Check deviations
     
Gradations in the surface 
(sawtooth pattern)
The secondary cutting edge or one or more inserts is not parallel with the bar Check the position of the secondary cutting edge and adjust if necessary

 

Feed/revolution is greater than the length of the secondary cutting edge Reduce feed
  Poor insert clamping
(dirt in insert seat)
Check clamping, clean insert seat
     
Poor chip formation Feed too low Increase feed
  Incorrect chip breaker Check chip breaker selection
  Insufficient coolant Increase amount of coolant
     
Chatter marks Incorrect support chamfer Check support chamfer
  Secondary cutting edge too sharp, "hacks into material" Apply rounding
  Cutting edge is too far below the centre Check height
  Guide rollers or jaws set incorrectly Check setting
     
Widely varying wear from one insert to the next Tool is incorrectly set 
(one insert is working with a larger depth of cut than the others)
Check tool setting
     
Cutting edge breakage Incorrect protective cutting edge chamfer Increase chamfer width, increase chamfer angle
  Feed too high Reduce feed
  Insufficient rounding Apply greater degree of rounding
  Incorrect grade in use Make provisions for tougher grade