Do you know the common problems and solutions for deep hole machining of cutting tools in machining centers?

“Common Problems and Solutions for Deep Hole Machining of Cutting Tools in Machining Centers”

1. The designed outer diameter of the reamer is too large or there are burrs on the cutting edge of the reamer.
2. The cutting speed is too high.
3. The feed rate is improper or the machining allowance is too large.
4. The main deflection angle of the reamer is too large.
5. The reamer is bent.
6. There are built-up edges attached to the cutting edge of the reamer.
7. The runout of the reamer cutting edge during grinding exceeds the tolerance.
8. The cutting fluid is improperly selected.
9. When installing the reamer, the oil stains on the taper shank surface are not wiped clean or there are dents on the taper surface.
10. After the flat tail of the taper shank is misaligned and installed in the machine tool spindle, the taper shank and taper interfere.
11. The spindle is bent or the spindle bearing is too loose or damaged.
12. The reamer’s floating is not flexible.
13. When hand reaming, the forces applied by both hands are not uniform, causing the reamer to sway left and right.
    (B) Solutions
14. According to the specific situation, appropriately reduce the outer diameter of the reamer to ensure that the tool size meets the design requirements. Before processing, carefully inspect the reamer and remove the burrs at the cutting edge to ensure the sharpness and accuracy of the tool.
15. Reduce the cutting speed. Excessive cutting speed will lead to increased tool wear, enlarged hole diameter, and other issues. According to different machining materials and tool types, select an appropriate cutting speed to ensure processing quality and tool life.
16. Appropriately adjust the feed rate or reduce the machining allowance. Excessive feed rate or machining allowance will increase the cutting force, resulting in an enlarged hole diameter. By reasonably adjusting the processing parameters, the hole diameter can be effectively controlled.
17. Appropriately reduce the main deflection angle. A too large main deflection angle will cause the cutting force to concentrate on one side of the tool, easily leading to enlarged hole diameter and tool wear. According to the processing requirements, select an appropriate main deflection angle to improve processing accuracy and tool life.
18. For a bent reamer, straighten it or scrap it. A bent tool cannot guarantee processing accuracy and may also damage the workpiece and machine tool.
19. Carefully dress the cutting edge of the reamer with an oilstone to remove the built-up edge and ensure that the cutting edge is smooth and flat. The existence of built-up edges will affect the cutting effect and lead to unstable hole diameter.
20. Control the runout of the reamer cutting edge during grinding within the allowable range. Excessive runout will cause the tool to vibrate during processing and affect processing accuracy.
21. Select a cutting fluid with better cooling performance. Appropriate cutting fluid can reduce cutting temperature, reduce tool wear, and improve the processing surface quality. According to the machining material and processing requirements, select an appropriate cutting fluid type and concentration.
22. Before installing the reamer, the oil stains inside the taper shank of the reamer and the taper hole of the machine tool spindle must be wiped clean. Where there are dents on the taper surface, dress it with an oilstone. Ensure that the tool is firmly and accurately installed to avoid processing problems caused by improper installation.
23. Grind the flat tail of the reamer to ensure its fitting accuracy with the machine tool spindle. Misaligned flat tail will cause the tool to be unstable during processing and affect processing accuracy.
24. Adjust or replace the spindle bearing. Loose or damaged spindle bearings will lead to spindle bending and thus affect processing accuracy. Regularly check the state of the spindle bearings and adjust or replace them in time.
25. Readjust the floating chuck and adjust the coaxiality. Ensure that the reamer is coaxial with the workpiece to avoid enlarged hole diameter and processing surface quality problems caused by non-coaxiality.
26. When hand reaming, pay attention to applying force evenly with both hands to avoid the reamer swaying left and right. Correct operation methods can improve processing accuracy and tool life.

1. The designed outer diameter of the reamer is too small.
2. The cutting speed is too low.
3. The feed rate is too large.
4. The main deflection angle of the reamer is too small.
5. The cutting fluid is improperly selected.
6. During grinding, the worn part of the reamer is not completely ground off, and elastic recovery reduces the hole diameter.
7. When reaming steel parts, if the allowance is too large or the reamer is not sharp, elastic recovery is prone to occur, reducing the hole diameter.
8. The inner hole is not round, and the hole diameter is unqualified.
   (B) Solutions
9. Replace the outer diameter of the reamer to ensure that the tool size meets the design requirements. Before processing, measure and inspect the reamer and select an appropriate tool size.
10. Appropriately increase the cutting speed. Too low cutting speed will lead to low processing efficiency and reduced hole diameter. According to different machining materials and tool types, select an appropriate cutting speed.
11. Appropriately reduce the feed rate. Excessive feed rate will increase the cutting force, resulting in a reduced hole diameter. By reasonably adjusting the processing parameters, the hole diameter can be effectively controlled.
12. Appropriately increase the main deflection angle. A too small main deflection angle will cause the cutting force to be dispersed, easily leading to reduced hole diameter. According to the processing requirements, select an appropriate main deflection angle to improve processing accuracy and tool life.
13. Select an oily cutting fluid with good lubrication performance. Appropriate cutting fluid can reduce cutting temperature, reduce tool wear, and improve the processing surface quality. According to the machining material and processing requirements, select an appropriate cutting fluid type and concentration.
14. Regularly interchange the reamer and correctly grind the cutting part of the reamer. Remove the worn part in time to ensure the sharpness and accuracy of the tool.
15. When designing the reamer size, factors such as the elastic recovery of the machining material should be considered, or values should be taken according to the actual situation. According to different machining materials and processing requirements, reasonably design the tool size and processing parameters.
16. Conduct trial cutting, take an appropriate allowance, and grind the reamer sharp. Through trial cutting, determine the optimal processing parameters and tool state to ensure processing quality.

1. The reamer is too long, lacking rigidity, and vibrates during reaming.
2. The main deflection angle of the reamer is too small.
3. The cutting edge band of the reamer is narrow.
4. The reaming allowance is too large.
5. There are gaps and cross holes on the inner hole surface.
6. There are sand holes and pores on the hole surface.
7. The spindle bearing is loose, there is no guide sleeve, or the fit clearance between the reamer and the guide sleeve is too large.
8. Due to the thin-walled workpiece being clamped too tightly, the workpiece deforms after removal.
   (B) Solutions
9. For a reamer with insufficient rigidity, a reamer with unequal pitch can be used to improve the rigidity of the tool. At the same time, the installation of the reamer should use a rigid connection to reduce vibration.
10. Increase the main deflection angle. A too small main deflection angle will cause the cutting force to be dispersed, easily leading to an unround inner hole. According to the processing requirements, select an appropriate main deflection angle to improve processing accuracy and tool life.
11. Select a qualified reamer and control the hole position tolerance of the pre-machining process. Ensure the quality and accuracy of the reamer. At the same time, strictly control the hole position tolerance in the pre-machining process to provide a good foundation for reaming.
12. Use a reamer with unequal pitch and a longer and more precise guide sleeve. A reamer with unequal pitch can reduce vibration, and a longer and more precise guide sleeve can improve the guiding accuracy of the reamer, thereby ensuring the roundness of the inner hole.
13. Select a qualified blank to avoid defects such as gaps, cross holes, sand holes, and pores on the inner hole surface. Before processing, inspect and screen the blank to ensure that the blank quality meets the requirements.
14. Adjust or replace the spindle bearing to ensure the accuracy and stability of the spindle. For the case without a guide sleeve, install an appropriate guide sleeve and control the fit clearance between the reamer and the guide sleeve.
15. For thin-walled workpieces, an appropriate clamping method should be used to reduce the clamping force and avoid workpiece deformation. During the processing, pay attention to controlling the processing parameters to reduce the influence of cutting force on the workpiece.

1. Excessive reaming allowance.
2. The rear angle of the cutting part of the reamer is too large.
3. The cutting edge band of the reamer is too wide.
4. There are pores and sand holes on the workpiece surface.
5. Excessive spindle runout.
   (B) Solutions
6. Reduce the reaming allowance. Excessive allowance will increase the cutting force and easily lead to ridges on the inner surface. According to the processing requirements, reasonably determine the reaming allowance.
7. Reduce the rear angle of the cutting part. A too large rear angle will make the cutting edge too sharp and prone to ridges. According to the machining material and processing requirements, select an appropriate rear angle size.
8. Grind the width of the cutting edge band. A too wide cutting edge band will make the cutting force uneven and easily lead to ridges on the inner surface. By grinding the width of the cutting edge band, make the cutting force more uniform.
9. Select a qualified blank to avoid defects such as pores and sand holes on the workpiece surface. Before processing, inspect and screen the blank to ensure that the blank quality meets the requirements.
10. Adjust the machine tool spindle to reduce the spindle runout. Excessive spindle runout will cause the reamer to vibrate during processing and affect the processing surface quality. Regularly check and adjust the machine tool spindle to ensure its accuracy and stability.

1. Excessive cutting speed.
2. Improperly selected cutting fluid.
3. The main deflection angle of the reamer is too large, and the reamer cutting edge is not on the same circumference.
4. Excessive reaming allowance.
5. Uneven reaming allowance or too small allowance, and some surfaces are not reamed.
6. The runout of the cutting part of the reamer exceeds the tolerance, the cutting edge is not sharp, and the surface is rough.
7. The cutting edge band of the reamer is too wide.
8. Poor chip removal during reaming.
9. Excessive wear of the reamer.
10. The reamer is damaged, and there are burrs or chipped edges on the cutting edge.
11. There is a built-up edge on the cutting edge.
12. Due to the material relationship, zero rake angle or negative rake angle reamers are not applicable.
    (B) Solutions
13. Reduce the cutting speed. Excessive cutting speed will lead to increased tool wear and increased surface roughness value. According to different machining materials and tool types, select an appropriate cutting speed.
14. Select a cutting fluid according to the machining material. Appropriate cutting fluid can reduce cutting temperature, reduce tool wear, and improve the processing surface quality. According to the machining material and processing requirements, select an appropriate cutting fluid type and concentration.
15. Appropriately reduce the main deflection angle and correctly grind the reamer cutting edge to ensure that the cutting edge is on the same circumference. A too large main deflection angle or a cutting edge not on the same circumference will make the cutting force uneven and affect the processing surface quality.
16. Appropriately reduce the reaming allowance. Excessive allowance will increase the cutting force and easily lead to an increased surface roughness value. According to the processing requirements, reasonably determine the reaming allowance.
17. Improve the position accuracy and quality of the bottom hole before reaming or increase the reaming allowance to ensure uniform reaming allowance and avoid some surfaces not being reamed.
18. Select a qualified reamer, regularly inspect and grind the reamer to ensure that the runout of the cutting part is within the tolerance range, the cutting edge is sharp, and the surface is smooth.
19. Grind the width of the cutting edge band to avoid the influence of too wide cutting edge band on the cutting effect. According to the processing requirements, select an appropriate cutting edge band width.
20. According to the specific situation, reduce the number of reamer teeth, increase the chip space or use a reamer with a cutting edge inclination to ensure smooth chip removal. Poor chip removal will lead to chip accumulation and affect the processing surface quality.
21. Regularly replace the reamer to avoid excessive wear. During processing, pay attention to observing the wear condition of the tool and replace the severely worn tool in time.
22. During grinding, use, and transportation of the reamer, protective measures should be taken to avoid damage. For a damaged reamer, use an extremely fine oilstone to repair the damaged reamer or replace it.
23. Remove the built-up edge on the cutting edge in time. The existence of built-up edges will affect the cutting effect and lead to an increased surface roughness value. By adjusting the cutting parameters and selecting an appropriate cutting fluid, the generation of built-up edges can be reduced.
24. For materials not suitable for zero rake angle or negative rake angle reamers, select an appropriate tool type and processing parameters. According to the characteristics of the machining material, select an appropriate tool and processing method to ensure processing surface quality.

1. Improper reamer material.
2. The reamer is burned during grinding.
3. Improperly selected cutting fluid, and the cutting fluid cannot flow smoothly. The surface roughness value of the cutting part and the reamer cutting edge after grinding is too high.
   (B) Solutions
4. Select the reamer material according to the machining material. Carbide reamers or coated reamers can be used. Different machining materials require different tool materials. Selecting an appropriate tool material can improve the tool life.
5. Strictly control the cutting parameters during grinding to avoid burning. When grinding the reamer, select appropriate cutting parameters to avoid overheating and burning of the tool.
6. Regularly select the cutting fluid correctly according to the machining material. Appropriate cutting fluid can reduce cutting temperature, reduce tool wear, and improve the processing surface quality. Ensure that the cutting fluid can flow smoothly to the cutting area and play its cooling and lubricating role.
7. Regularly remove the chips in the chip groove and use cutting fluid with sufficient pressure. After fine grinding or lapping, meet the requirements. Removing chips in time can avoid chip accumulation and affect the cutting effect and tool life. At the same time, using cutting fluid with sufficient pressure can improve the cooling and lubricating effect.

1. Wear of the guide sleeve.
2. The bottom end of the guide sleeve is too far from the workpiece.
3. The guide sleeve is short in length and poor in accuracy.
4. Loose spindle bearing.
   (B) Solutions
5. Regularly replace the guide sleeve. The guide sleeve will gradually wear during processing and affect processing accuracy. Regularly replace the guide sleeve to ensure its accuracy and guiding function.
6. Lengthen the guide sleeve and improve the fitting accuracy between the guide sleeve and the reamer clearance. If the bottom end of the guide sleeve is too far from the workpiece or the guide sleeve is short in length and poor in accuracy, the reamer will deviate during processing and affect the hole position accuracy. By lengthening the guide sleeve and improving the fitting accuracy, the processing accuracy can be improved.
7. Timely repair the machine tool and adjust the spindle bearing clearance. Loose spindle bearings will cause the spindle to swing and affect processing accuracy. Regularly check and adjust the spindle bearing clearance to ensure the accuracy and stability of the machine tool.

1. Excessive reaming allowance.
2. The workpiece material is too hard.
3. Excessive runout of the cutting edge, and uneven cutting load.
4. The main deflection angle of the reamer is too small, increasing the cutting width.
5. When reaming deep holes or blind holes, there are too many chips and they are not removed in time.
6. The teeth are cracked during grinding.
   (B) Solutions
7. Modify the pre-machined hole diameter size and reduce the reaming allowance. Excessive allowance will increase the cutting force and easily lead to chipped teeth. According to the processing requirements, reasonably determine the pre-machined hole diameter size and reaming allowance.
8. Reduce the material hardness or use a negative rake angle reamer or carbide reamer. For workpiece materials with excessive hardness, methods such as reducing the material hardness or selecting a tool type suitable for hard material processing can be used.
9. Control the runout within the tolerance range to ensure uniform cutting load. Excessive runout of the cutting edge will make the cutting force uneven and easily lead to chipped teeth. By adjusting the tool installation and processing parameters, control the runout within the tolerance range.
10. Increase the main deflection angle and reduce the cutting width. A too small main deflection angle will increase the cutting width and easily lead to chipped teeth. According to the processing requirements, select an appropriate main deflection angle size.
11. Pay attention to removing chips in time, especially when reaming deep holes or blind holes. Chip accumulation will affect the cutting effect and easily lead to chipped teeth. Use an appropriate chip removal method to remove chips in time.
12. Pay attention to grinding quality and avoid the teeth being cracked during grinding. When grinding the reamer, select appropriate cutting parameters and grinding methods to ensure the quality and strength of the teeth.

1. Excessive reaming allowance.
2. When reaming tapered holes, the distribution of rough and finish reaming allowances and the selection of cutting parameters are inappropriate.
3. The chip space of the reamer teeth is small,