Determining causes for machining chatter, tool chatter or part finish problems
- Which axis or axes?
- One tool or multiple?
- Is it at a quadrant?
- Are you having problems with size varying?
- Was the job just setup?
- Was the machine crashed recently?
- Is this a different batch of parts or different lot of castings?
- Harder material or improper hardening?
- Have you been changing inserts more often?
- Is it an interrupted cut?
- Is the material casting more porous then usual?
- Is it on both pallets?
- Changing the RPM? Could it be at critical speed?
- Is there any vibration coming through the floor from other equipment?
- Are you filling the lube pump less than before?
- Are you filling the lube pump more that usual?
Cutter chatter and machining finsh problems checks and troubleshooting:
- Check that the finish tool is not dull, chipped or broken
- Make sure the coolant is flushing properly throughout the cut and is pointed away from the tool,not toward it
- Make sure your breaking the chip properly and not making spirals
- Check to make sure the finisher is not taking off too much in one pass measure after roughing
- Make sure an insert is made for the material you are cutting
- Check feed rate and spindle speed
- Check the hardness of the parts
- If lathe check to make sure it is on the centerline of the part
- Try a different tool holder
Common machine problems of poor part finish and machine accuracy.
- Is the machine level?
- Are all of the feet touching the pads?
- Check the backlash?
- Try slower feed
- Parts harder or more porous (castings)
- Check gibs for play
- Bearings or ballscrew bad
- Is the axis loud in rapid?
- Broken lube line
- Lube pump strainer clogged
- Metering block faulty
- Improper oil in lube pump reservoir.
- Tool clamp pressure low
- Coolant issues- low, mixture, contaminated, etc.
- New tooling, are they balanced?