How Chemistry Determines Machinability- Manganese Sulfides
Manganese sulfides are the reason that we can get improved surface finishes and higher surface footages with reduced flank wear from 11XX and 12XX series steels.
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The Point of the Tool Seldom Cuts
The process of creating a chip can be seen in this video.
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Built Up Edge-What It Is And What To Do
Built up Edge can add tool life when it is stable or give the machinist fits when it is unstable and out of control. Several tips for understanding BUE are given in this post.
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The Chatter About Chatter
If forced vibration is what you have, confirming the integrity of the machine tool and its power train is a critical first step. Reducing the feed per revolution is one way to determine if it is the variation in the cutting process that is forcing the vibration. Changing the SFM or rpm’s by at least 25% is also something to try (increase or decrease!)
To eliminate self excited chatter decrease the length of the tool in the cut, and substitute more rigid tooling and support materials (a carbide boring bar deflects less and can make three or more times heavier a cut than one made of steel for example) .