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Indexable insert drilling problems, causes and solutions

The 12 most common indexable insert drilling problems and causes – and how you can avoid them!

Rotating and stationary application

Hole tapers in

  • Chip jam on the outer cutting edge → use a different chip breakage geometry, increase the feed if necessary
  • Material very soft → increase the cutting speed, reduce the feed
  • Use positive cutting edge geometry

Hole tapers out

  • Chip jam on the inner cutting edge → use a different chip breakage geometry, increase the feed if necessary

Short service life / types of wear of indexable inserts

  • Cutting speed too high → select the correct cutting speed
  • Cutting material has too little wear resistance → select a wear resistant grade
  • Tool overhang too large → if possible, use a shorter tool
  • Damaged insert seat → check tool, replace if necessary
  • Clamping device stability too low → increase stability

Friction marks on the tool shank

  • Bore diameter too small → check the setting
  • Chip evacuation problems → optimise the cutting parameters, check the geometry of the indexable insert
  • Cutting radius too high → use the correct cutting radius

Poor surface quality

  • Poor chip evacuation → optimise the cutting parameters: Increase cutting speed
  • Reduce feed

Built-up edge formation

  • Cutting speed too low → increase cutting speed
  • Indexable insert too negative → use positive geometry
  • Unsuitable coating → select the correct coating

Stationary application

Edge breakage on the inner cutting edge

  • Centre height of the tool too high/too low → adjust tool turret/adapter if necessary → recalibrate the machine
  • Indexable insert grades interchanged → use correct indexable insert
  • Feed too high → reduce feed
  • Indexable insert grade too brittle → use a tougher indexable insert grade
  • Incorrect indexable insert geometry → if necessary use a geometry with a chamfered cutting edge

Edge breakage on the outer cutting edge

  • Feed too high → reduce feed
  • Interrupted cut → switch to a tougher grade of indexable insert
  • Cutting radius too small → use an indexable insert with a larger cutting radius

Hole too small / too large

  • Machine is not in the X-0 position → move axis to correct position
  • Machine axis has been moved → recalibrate the machine

Rotating application

Edge breakage on the inner cutting edge

  • Indexable insert grades interchanged → use correct indexable insert
  • Feed too high → reduce feed
  • Indexable insert grade too brittle → use a tougher indexable insert grade
  • Incorrect indexable insert geometry → if necessary use a geometry with a chamfered cutting edge

Edge breakage on the outer cutting edge

  • Feed too high → reduce feed
  • Interrupted cut → switch to a tougher grade of indexable insert
  • Cutting radius too small → use an indexable insert with a larger cutting radius

Hole too small / too large when using adjustable tools

  • Incorrect cutting radius used → use the correct cutting radius
  • Incorrect setting → use the correct tool setting
  • Increase cutting fluid supply

Should you have any further questions, our consulting service is ready to help.

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More about indexable insert drilling:

How to find the perfect indexable insert drill for your application

 Coding examples for indexable insert drilling & recommended coolant pressure/flow

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