Chips clog or jam (milling, end milling)

?Likely causes

• Chips have no escape route, as in slottingOne maker^[1]
• Chip pocket is small or there are too many teethAgreed by 2+ makers^{[2][3][4][5][6]}
• Depth of cut (cutting volume) is largeOne maker^[2][3]
• Welding is occurringOne maker^[4][5]
• Chips are too thin (feed is small)One maker^[4][5]
• Chip evacuation by coolant or air is insufficientAgreed by 2+ makers^[1][4][5][7]

✓Fixes

Cutting conditions

• Divide deep slots into multiple passes with a smaller depth of cutAgreed by 2+ makers^[1][3][2]
• In deep slotting, reduce the feed (Sandvik); if chips are too thin, increase the feed (Mitsubishi)Agreed by 2+ makers^[1][4]
• Use climb milling to avoid recutting chipsOne maker^[8]

Tool

• Use a tool with fewer teeth and a larger chip pocketAgreed by 2+ makers^{[1][2][3][4][6]}
• Use a roughing end mill or a nicked end millAgreed by 2+ makers^[2][8]

Coolant

• Blow chips away with sufficient coolant or air blow (through-tool coolant if possible)Agreed by 2+ makers^[1][4][7][8]

▦Notes by material

• Titanium alloy: Chip recutting tends to occur in slotting and pocketing, leading to chipped cutting edges^[1]

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