Machining is a complex and precise process, and even small errors can result in wasted materials/time. The five most common causes of machining mistakes are probably:
- Using the wrong tool
- Using incorrect setups, e.g. speeds/feeds
- Poor chip control
- Poor/incorrect maintenance
- Lack of adequate training.
Using the Wrong Tool/Tools
This is a very common mistake. Using the incorrect tool can cause issues with rapid tool wear, poor finishes and even damage to workpieces.
This can be avoided by having clear processes and criteria in place prior to starting a job. The tool should be selected based on key project requirements and important factors such as material thickness, hardness and heat-resistance.
Using Incorrect Speeds and Feeds
Using the wrong speeds and feeds can cause a number of issues, ranging from poor finishes to tool breakage. This is especially true when machining harder materials.
To combat this, ensure that speeds and feeds are set to optimal levels based on the material and tool being used. It can often also be worth machining a ‘practice’ piece.
Tapping Machines
Roscamat tapping machines are widely regarded as being some of the best available. There are a number of companies with expertise in this field, including Cotswold Machinery Sales and several others.
Poor Chip Control
Accumulated chips can cause clogs in cutting areas, damage workpieces and reduce cooling. They need to be removed. Tools with built-in chip breakers can help, as can making sure that coolant flows freely.
Insufficient Tool Maintenance
Neglecting tool maintenance can result in issues with quality, consistency, precision and more.
To combat this, ensure that all tools are inspected and cleaned regularly by adding these tasks to workflow/timetables. Also, make sure that all tools are correctly stored, and replace tools at the first signs of wear.
Lack of Adequate Training
Sufficient training is crucial due to the precise nature of machining. Without this, mistakes can easily be made. Investment in training pays off in the short and long term. Knowledge is critical when using machining tools.