Cutting edge chipping

?Likely causes

• Unstable machining (vibration, insufficient mounting rigidity)Agreed by 2+ makers^{[1][2][3][4][5]}
• Grade is too hard or brittleAgreed by 2+ makers^[1][6][5][3]
• Insufficient edge strength (small honing, weak edge geometry)Agreed by 2+ makers^[6][4][5][3]
• Feed is largeAgreed by 2+ makers^[5][7][8][9]
• When welded material or built-up edge breaks away, it takes part of the cutting edge with itAgreed by 2+ makers^[2][6][4]
• Chips hit or get jammed against the cutting edgeAgreed by 2+ makers^[1][6][5][8]
• Thermal cracks or boundary wear act as the starting pointOne maker^[4][5]
• Tool runout is largeAgreed by 2+ makers^[8][10][11]
• Chuck is not tightened enoughAgreed by 2+ makers^[9][12]
• CVD coating is thickOne maker^[1]

✓Fixes

Cutting conditions

• Reduce the feed and depth of cut, and reduce the feed at entryAgreed by 2+ makers^{[6][3][4][8][9]}

Tool

• Use a tougher gradeAgreed by 2+ makers^{[1][6][2][3][4]}
• Use larger honing and an edge geometry with higher edge strength (smaller rake angle)Agreed by 2+ makers^{[1][2][3][5][4]}
• Add a small chamfer or radius to the end mill cornerAgreed by 2+ makers^[8][12]

Setup

• Increase mounting rigidity to suppress vibrationAgreed by 2+ makers^[1][3][5][4]
• Reduce tool runoutAgreed by 2+ makers^[8][10]
• Use a tool path and breaker that keep chips from hitting the cutting edgeAgreed by 2+ makers^[1][8]
• Make sure the chuck or collet is tightened securelyAgreed by 2+ makers^[9][12][13]

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