Troubleshooting
PROBLEM | CAUSE | REMEDY |
Poor surface finish in drilled hole | 1. Cutting speed too low, support pads experiencing build up and galling hole surface. | Increase speed (RPM) |
2. Wrong cutting oil, temperature too high, over 135F. Sulfur or lubricant is being disapated by heat. | Check oil sample. | |
3. Poor filtration, small particles being reproduced over support pads. | Increase filtration (40 microns) | |
4. Worn support pads. | Replace drill and check (RPM). Check for proper drill grades. | |
5. Vibration, unstable machine or fixturing. | Strengthen machine &/or set up. | |
Chip jamming in the drill or tube | 1. Inadequate cutting fluid volume. | Check pump, fluid viscosity, and filter. Check pump rotation. Check the plumb between pump and connector. Check slope of drain line to tank. |
Correct volume and pressure but cutting fluid is not reaching drill adequately | 1. Inner tube too short in relation to outer tube. | Replace with correct length. |
2. Worn support surface in sealing sleeve for inner tube or missing "o" ring in I.D. of sealing sleeve. | Replace sealing sleeve or inner "O" ring. | |
3. Venturi slots of inner tube are worn so that excessive amount of cutting fluid escapes the exhaust. | Replace inner tube. | |
4. Clogged exhaust line, blocked inner tube. | Clear blockages. | |
Cutting fluid leaks out between drill brushing and outer tube excessively | 1. Chip jamming in drill or flare in inner tube. | Clear system blockages. |
2. Exhaust line does not slope towards chip disposal area. | Adjust line in downward position. | |
3. Inner tube inverted in wrong direction. | Correct direction (flare in drill). | |
Drill breakage or insert or inserts chipping prematurely, despite good chip-breaking. | 1. Poor chip evacuation. | Check I.D. of the connections for blockage, slope of drain line, if inner tube is constricted or if venturi slots are deformed. |
2. Chip jamming in drill or inner tube. | Built up edge on the central tip can cause crumbling so that long chips form and block chip flow. Decrease feed per revolution. | |
3. Incorrect start of drilling I.e. center drilled hole, irregular surface, oversize bushing. | Check stability of workpiece. Replace worn bushing. Check alignment of bushing. Enlarge center hole so periphery cuts 1st or reduce so central cuts 1st. | |
4. Cross drilling (intersecting holes) | Use EDGE cross-hole adapters. | |
5. Overloading of the insert. | Decrease feed per revolution. | |
6. Lack of stability. | Strengthen machine or fixture, check connections / connector. | |
Center line deviation of hole. | 1. Machine is out of alignment. | Align machine (.001"T.I.R. head stock to tailstock or fixture. |
2. Component is misaligned. | Align component (same tolerance as machine). | |
3. Oversize bushing | Replace bushing | |
4. Excessive tube length. | Apply tube support (every 48"). | |
5. Workpiece material(e.g. cast iron often gives poor support). | Adjust cutting data. | |
Premature tool life and or insert breakage. | 1. Cutting speed and feed too low. | Increase cutting data. |
2. Misalignment (machine & component). | Align machine (.001"T.I.R.) | |
3. Cutting speed too high. | Reduce cutting speed. | |
4. Heavy wear on support pad & peripheral. | Change cutting fluid. Check fluid filtration. Check bushing wear & be sure it is within tolerances. | |
5. Unsuitable drill grade. | Switch to recommended grade. | |
6. Incorrect G.P.M. and P.S.I., or poor quality coolant. | Check volume and pressure. | |
Oversize hole. | 1. New drill. | Hone periphery corner. |
2. Oversize bushing or misalignment of bushing. | Replace bushing, realign bushing (.001"T.I.R.) | |
3. Instable machine or set up. | Stabilize machine or fixture. | |
Spiraling effect in hole. | 1. Fragmented support pad. | Replace drill. |
2. Misalignment of machine or component. | Align machine or component (.001"T.I.R.) | |
3. Lack of lubricity in coolant | Increase additives (E.P., sulfur). | |
4. Lack of coolant volume. | Check for blockages, adjust pressure relief valve, check tubes. | |
Bell mouth at start of hole. | 1. Oversize bushing. | Replace bushing. |
2. Lack of rigidity in bushing housing. | Strengthen housing. |