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    Threading 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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