Types of Cutting That Causes Material Damage in CNC Machining

Posted On: November 17, 2022

Tool deformation and material damage are common issues faced by CNC machine users. Several factors are responsible for the damage and deformation of the tools used in CNC machines. Hence it is essential to inspect the tool properly to prevent it from damage. Before this, it is important to understand the factors that cause tool deformation and material damage in CNC machines. This post talks about the types of cutting problems that lead to tool deformation and material damage in CNC machines.

3 Common Tool Cutting Problems in CNC Machining Discussed

CNC machining is a computer-controlled process; still, machine tools may not work as expected. Irregular cutting of work objects is one such issue. Below given are three common tool-cutting problems faced by CNC machine operators. 

1.Hitting Cutters: This is the condition where the cutting tool cuts a large amount of workpiece material and hits it during the process. This collision between the workpiece and the cutting tool not only produces high vibration but also damages the workpiece. See the below given reasons and tips to avoid hitting cutters. 

• High Cutting Amount: Large tool diameter is one of the reasons for the high cutting amount, and this can be easily reduced by choosing a tool with a small cutting diameter. The cutting amount can be set for methods. For instance, finishing and semi-finishing require a small tool diameter. 
• Inappropriate Machining Method: It is essential to select a proper machining method according to the tool type and work requirement. For instance, if the tool diameter is small, contour milling is acceptable, but it’s better to select cavity milling if the tool diameter is large.
• Improper Safety Heights: It’s essential to select an appropriate safety height to avoid hitting the clamping during tool lifting. Hence, it’s better to keep the safety height higher than the clamping height.

2.Bouncing Cutters: Bouncing cutters can cause tool deformation and material damage in CNC machines. It generally occurs due to the significant vibrations caused by excessive force on the tools. The primary reasons that influence bouncing cutters are as follows:

• Tool diameter is one of the most important reasons for bouncing cutter. If you choose a tool with the same length and diameter and reduce the diameter by one time, this accelerates the deformation by at least four times. Therefore, it is always better to choose tools of large diameters than lengths, as this will help avoid vibrations. 
• Tool length is another concern for bouncing cutters. If you choose a tool with the same diameter and length and increase the length later, the deformation will increase thrice. Thus, to avoid it, use a tool that is shorter than the diameter.
• The force received by the tool during the cutting is directly proportional to its deformation. Although the force cannot be eliminated from the process, but it can definitely be reduced to avoid bouncing cutters.

3. Overcutting: This means cutting part of the work piece more than required. This can damage the workpiece. To avoid the occurrence of overcutting, it’s always advisable to keep an eye on the tool path. In addition to this, it is also very essential to be careful and meticulous while cutting with the tool.

It is essential to keep these things in mind to minimize the risk of tool failure and material damage, as this may lead to production downtimes. If you have been thinking of sourcing your CNC machining services, ensure you partner with trusted services like BDE, Inc. The company offers a wide range of machining processes and adheres to ASNI, ASME, ASTM, Mil-Spec, ISO, and RoHS processes