End mill breaks

?Likely causes

• Feed is largeAgreed by 2+ makers^[1][2][3]
• Depth of cut is largeAgreed by 2+ makers^[1][2][4]
• Overhang is longer than necessaryAgreed by 2+ makers^[1][2][3][4]
• A low-rigidity end mill is being usedOne maker^[1][4]
• Chips are cloggedAgreed by 2+ makers^[4][3]
• Wear is advanced, or the collet is worn outAgreed by 2+ makers^[2][3]
• Shock at entry, at exit, and when the feed direction changesOne maker^[3]

✓Fixes

Cutting conditions

• Reduce the feedAgreed by 2+ makers^[1][2][3]
• Reduce the depth of cutAgreed by 2+ makers^[1][2][4]
• For changes in feed direction, use circular interpolation or a dwell, and reduce the feed before and afterOne maker^[3]

Tool

• Use a high-rigidity end mill or a roughing end millAgreed by 2+ makers^[1][2][4]
• Replace or regrind earlyAgreed by 2+ makers^[2][3]
• Reduce the number of teeth to prevent chip cloggingAgreed by 2+ makers^[3][4]

Setup

• Keep the overhang to a minimumAgreed by 2+ makers^[1][2][3][4]
• Replace the chuck or colletAgreed by 2+ makers^[2][3]

Coolant

• Increase the cutting fluid flow (switch from dry to wet)Agreed by 2+ makers^[4][3]

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