Edge chipping (workpiece edge breaks off)

?Likely causes

• Feed or depth of cut is largeAgreed by 2+ makers^{[1][2][3][4][5]}
• Cutting direction in which the edge exits the workpiece (exit of up milling, entry of climb milling)Agreed by 2+ makers^[4][5]
• Cutting edge is dullAgreed by 2+ makers^[3][6][1][2]
• Corner angle of the face mill is smallOne maker^[3][6]
• Vibration is occurringOne maker^[2][3][6]
• Exit of brittle materials such as cast ironOne maker^[2][7]

✓Fixes

Cutting conditions

• Reduce the feed and depth of cutAgreed by 2+ makers^{[1][2][3][4][5]}
• Reduce the feed at the exit (or entry) and adjust the tool pathAgreed by 2+ makers^[5][4]
• Use climb milling for end millsOne maker^[4][8]

Tool

• Use a sharp cutting edge (large rake angle, small honing)Agreed by 2+ makers^[3][6][1][2]
• Increase the corner angle (side cutting edge angle) and corner radiusAgreed by 2+ makers^[3][6][1][2]

Setup

• Increase tool and workpiece mounting rigidity to suppress vibrationAgreed by 2+ makers^[1][2][3]
• Change the cutter position to make chips thinner at the exitOne maker^[9]

▦Notes by material

• Cast iron: Edge chipping at the exit is the typical trouble^[2][7]

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