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Thread Inserts Wear Problems and Solutions

Turn Thread
Mill Thread


Type of Wear
    • ×
      Plastic Deformation
      Plastic Deformation
      Cause
      • Excessive heat in cutting zone
      • Wrong Grade
      • Inadequate coolant supply
      • Depth of cut too large
      • Cutting speed too high
      • Nose radius too small

      Remedy
      • Reduce RPM/reduce depth of cut/check turned dia.
      • Use coated grade/use harder grade
      • Apply coolant
      • Reduce depth of cut /increase no. of passes
      • Reduce cutting speed
      • If possible use insert with larger radius
    • ×
      Premature Wear
      Premature Wear
      Cause
      • Cutting speed too high
      • Infeed depth too small
      • Highly abrasive material
      • Inadequate coolant supply
      • Wrong inclination anvil
      • Wrong turned dia. prior to threading
      • Insert is above center line

      Remedy
      • Reduce RPM
      • Modify flank infeed /increase depth of cut
      • Use coated grade
      • Apply coolant
      • Reselect anvil
      • Check turned dia.
      • Check center height
    • ×
      Insert breakage
      Insert Breakage
      Cause
      • Wrong turned dia. prior to threading
      • Wrong Grade
      • Poor chip control
      • Incorrect center height

      Remedy
      • Check turned dia.
      • Use tougher grade
      • Change to M/B type inserts and use modified flank infeed
      • Check center height
    • ×
      Built-up Edge
      Built-up Edge
      Cause
      • Cutting edge too cold
      • Wrong grade
      • Inadequate coolant supply
      • Incorrect cutting speed

      Remedy
      • Increase RPM /increase depth of cut
      • Use coated grade
      • Apply coolant
      • Change cutting speed
    • ×
      Vibration
      Vibration
      Cause
      • Incorrect workpiece clamping
      • Incorrect tool setup
      • Incorrect cutting speed
      • Incorrect center height

      Remedy
      • Use soft jaws
      • Check tool overhang / use anti vibration bars
      • Increase cutting speed
      • Check center height
    • ×
      Poor Surface Finish
      Poor Surface Finish
      Cause
      • Wrong cutting speed
      • Excessive heat in cutting zone
      • Poor chip control
      • Inadequate coolant supply
      • Wrong inclination anvil
      • Tool overhang too long
      • Incorrect center height

      Remedy
      • Increase/reduce RPM
      • Reduce depth of cut
      • Modify flank infeed
      • Apply coolant
      • Reselect anvil
      • Reduce tool overhang
      • Check center height
    • ×
      Poor Chip Control
      Poor Chip Control
      Cause
      • Excessive heat in cutting zone
      • Wrong grade
      • Inadequate coolant supply
      • Wrong turned dia. prior to threading
      • Incorrect method of infeed

      Remedy
      • Reduce RPM /change depth of cut /check turned dia.
      • Use coated grade /check turned dia./use M/B type inserts
      • Apply coolant
      • Check turned dia.
      • Modified flank infeed 3-5°
    • ×
      Thread Profile is Too Shallow
      Thread Profile is Too Shallow
      Cause
      • Incorrect center height
      • Worn insert
      • Insert isn’t machining the tread crest
      • Excessive wear

      Remedy
      • Check center height
      • Change to new cutting edge sooner
      • Check the workpiece dia.
      • Increase radial infeed
    • ×
      Broken Nose During First Pass
      Broken Nose During First Pass
      Cause
      • Cutting edge too cold
      • Depth of cut too large
      • Wrong grade
      • Wrong turned dia. prior to threading
      • Incorrect center height
      • Infeed depth too shallow
      • Wrong inclination anvil
      • Tool overhang tool long

      Remedy
      • Increase RPM
      • Reduce depth of cut/increase number of infeed passes
      • Use tougher grade
      • Check turned dia.
      • Adjust center height
      • Modify flank infeed
      • Reselect anvil
      • Reduce tool overhang
    • ×
      Incorrect Thread Profile
      Incorrect Thread Profile
      Cause
      • Unsuitable thread profile
      • Incorrect center height
      • Incorrect pitch in the program

      Remedy
      • Adjust to correct tool ,anvil and insert
      • Adjust center height
      • Change the program
    • ×
      Flank Wear
      Flank Wear
      Cause High cutting speed
      Remedy Reduce cutting speed
         
      Cause Chip too thin
      Remedy Increase feed rate and reduce radial passes
         
      Cause Insufficient coolant
      Remedy Check coolant pressure / flow direction
    • ×
      Fracture/Chipping
      Fracture/Chipping
      Cause Vibration
      Remedy Check stability
         
      Cause High load on cutting edge
      Remedy Reduce feed rate
      Add radial passes
    • ×
      Build up Edge
      Build up Edge
      Cause Cutting speed too low
      Remedy Increase cutting speed
         
      Cause Insufficient coolant
      Remedy Check coolant pressure / flow direction
    • ×
      Thread Surface-Chatter Marks/Vibrations
      Thread Surface-Chatter Marks/Vibrations
      Cause Feed rate is too high
      Remedy Reduce feed rate
         
      Cause Large profile
      Remedy Add passes
         
      Cause Thread length too long
      Remedy Add radial passes
      Reduce overhang
    • ×
      Thread Accuracy (GO/NOGO Gauge)
      Thread Accuracy (GO/NOGO Gauge)
      Cause Tool deflection
      Remedy Reduce feed rate
      Add radial passes
      Use ZERO compensation
         
      Cause CNC program error
      Remedy Check CNC program
    • ×
      Insert/Tool Breakage
      Insert/Tool Breakage
      Cause High load on the cutting edge
      Remedy Add radial passes
         
      Cause Unproper cutting conditions
      Remedy Adjust cutting conditions
         
      Cause Chip evacuation
      Remedy Add sufficient coolant
         
      Cause CNC program error
      Remedy Check CNC program
    • ×
      Tapered Thread
      Tapered Thread
      Cause Tool cutting load
      Remedy Add radial passes and/or reduce cutting conditions
         
      Cause Tool overhang
      Remedy Clamp tool to the minimum overhang length
    • ×
      Short Tool Life
      Short Tool Life
      Cause Unsuitable cutting conditions
      Remedy Adjust feed/speed
         
      Cause Vibrations
      Remedy Reduce overhang as short as possible
      Check tool and workpiece clamping
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