3 Common Tool Cutting Problems in CNC Machining Discussed

Tool deformation and material damage are common problems faced by CNC machine users. There are several factors that contribute to tool damage and deformation used in CNC machines. Therefore, it is important to properly inspect the tool to prevent it from getting damaged. Before that, it is important to understand the factors that cause tool deformation and material damage in CNC machines. This post discusses the types of cutting problems that lead to tool deformation and material damage in CNC machines.

CNC machining is a computer-controlled process; but the machine tool may not work as expected. Irregular cutting of the workpiece is one such problem. Given below are three common tool cutting problems faced by CNC machine operators.

1.Impact Tools in CNC Machining

This is a situation where the cutting tool cuts a large amount of workpiece material and hits the workpiece during machining. The collision between the workpiece and the cutting tool not only creates high vibrations but also damages the workpiece. See the reasons and tips to avoid tool impact given below.

1) High Cutting Volume

The large tool diameter is one of the reasons for the large amount of cutting, and the amount of cutting can be easily reduced by selecting a tool with a small cutting diameter. The CNC machining method can set the amount of cutting, such as finishing and semi-finishing requires a smaller tool diameter.

2) Improper machining method

It is important to select the appropriate machining method based on the tool type and job requirements. For example, if the tool diameter is small, contour milling can be performed, but if the tool diameter is large, it is better to choose cavity milling.

3) Improper safety height

It is very important to choose the right safety height to avoid hitting the clamping device when lifting the tool. Therefore, it is best to keep the safety height higher than the clamping height.

2.Tool jumping

Tool jumping can cause tool deformation and material damage in CNC machines. This usually occurs due to significant vibration caused by excessive force on the tool. The main reasons that affect tool jumping are as follows:

1) Tool diameter

If you choose a tool with the same length and diameter and reduce the diameter by half, this will accelerate the deformation at least four times. Therefore, it is always better to choose a tool with a diameter greater than the length because this helps avoid vibration.

2) Tool length

If you choose a tool with the same diameter and length, and then increase the length, the deformation will increase three times. Therefore, to avoid this, use a tool that is shorter than the diameter.

3) The force to which the tool is subjected during cutting is proportional to its deformation

While it is impossible to eliminate force from the process, it can be reduced to avoid tool jumping.

3.Overcutting

This means cutting a portion of the workpiece more than required. This can damage the workpiece. To avoid overcutting, it is always advisable to keep a close eye on the tool path. In addition to this, it is also very important to be careful when cutting with the tool.

These considerations must be kept in mind to minimize the risk of tool failure and material damage during CNC machining, which could result in production downtime.