Change to band with gage that is not too heavy for diameter of wheels and speed of machine

Band binding in cut , decrease feeding pressure

Adjust band for alignment on top and bottom wheels

Increase feeding pressure

Apply cutting fluid

Hold work firmly

Apply proper cutting fluid when cutting ferrous and nonferrous materials

Check periphery of wheels for defects

Make sure saw blade body is flat

Reduce feed pressure

Use band with coarser pitch

A dull or a blade with teeth having too high a rake angle can cause burrs

Feed rate too fast in thin work sections

If worn replace with new

Pitch too great for section being cut

Apply cutting fluid

Use band with finer pitch

Reduce rake and clearance angles

Decrease band tension

Check blade tension

Increase or decrease band tool velocity on the material being cut

Use band with coarser pitch to permit greater tooth penetration

Use band with coarser pitch

Use band with finer pitch

Properly adjust band tool guides

Unbalanced set or partial dullness caused by striking hard inclusion in material being cut

Increase blade tension

Adjust guides close to work

Lower band velocity

Feeding pressure or rate of feed too high , reduce feeding pressure

Keep teeth engaged

Decrease feeding force

Use a blade with a coarser pitch and/ or one with deeper gullets to prevent chip overloading

Saw guides too far apart , adjust closer to work

Increase feeding pressure

Cutting fluid mixture too thin

Reduce spped and/ or feed

Use band with finer pitch

Apply cutting fluid

Replace worn blade and/ or blade holders

Do not allow the teeth to idle through cut

Increase pitch too prevent tooth gullets from becoming choked with chips

Apply cutting fluid to help reduce this trouble

Check Work clamping

Reduce band tool velocity

Saw guides out of adjustment

Check Blade holding pins

Use band with coarser pitch

Check saw guide backup bearing ; if worn or unbalanced , replace same

Increase band velocity

Feeding pressure too heavy

Avoid starting cuts on sharp corners or thin sections

Carefully readjust guide inserts or rollers

Reduce feed pressures

Cutting speed too slow

In the case of brush equipped cut off machines , make sure brushes are properly adjusted

Clearance angles too great

Use a blade with a finer pitch

Check clamping of work

Band riding too heavy on saw guide backup bearing

Apply cutting fluid at point of cut, saturating the teeth evenly when cutting ferrous and nonferrous alloys

Increase band tension

Increase band tension

Check machine alignment and adjustments

Check alignment of band carrier wheels

Increase flow of cutting fluid

Make sure work is securely clamped

Use cutting fluid on ductile materials

Use a blade with a finer or coarser pitch

Increase blade tension

If worn replace same

Eliminate vibration by holding work firmly while it is fed into band

Decrease feeding force

Increase band velocity

Band too wide for radii being cut

Check sharpness of blade

Use slower feeding rate

Adjust or repair machine

Make sure teeth are flat across tops and/ or equally chamfered

Change cutting fluid

Use a blade with a finer or coarser pitch

Decrease band tension

Check alignment of work in holder and work material for hard spots

Side inserts or rollers of saw guides adjusted too close to band tool

Increase feeding pressure

Be sure band is running with teeth pointing down

Decrease band velocity

Apply cutting fluid

Wrong width band tool for radii

Reduce feed rate

Use fine pitch bands with thin work sections

If hunting back and forth against saw guide backup bearing , reweld with back of band in true alignment

Increase blade tension

Reduce speed and/ or feed

If gullets are loading , use heavier duty cutting fluid

Pitch too coarse , decrease unit load by using finer pitch

Check machine for adjustment

Lower band velocity

If clicking against saw guide backup bearing , remove burr on back of band where joined

Check and maintain tooth geometry

Reduce feed

Replace worn blade

Cutting speed too fast

Cracking at weld , Try longer annealing period decreasing heat gradually

Reduce feed pressure and/ or speed

Apply cutting fluid

Too few teeth in simultaneous cantact

VS

Check broach design to different geometry or provide shear on teeth

Abrasive action, mechanical shock and chemical reaction

OBS

Sharpen cutter or index inserts

Abrasive action, mechanical shock and chemical reaction

OBS

Reduce cutting speed

Abrasive action, mechanical shock and chemical reaction

OBS

Increase feed rate

Abrasive action, mechanical shock and chemical reaction

OBS

Use crabide grade having higher abrasive resistance

Addition of residual stresses from milling

VS

Adjust blast parts after milling to change stresses

Addition of residual stresses from milling

VS

Adjust Radial depth of cut

Addition of residual stresses from milling

VS

Use sharp cutters

Addition of residual stresses from milling

VS

Adjust feeds, speeds

Addition of residual stresses from milling

VS

Provide relief to minimize rubbing

Bent bar stock

PPS

Correct the incoming material

Bent or oversize barstock

PPS

Correct the incoming material

Bent reamer shank

OBS

Replace reamer

Brake cam set incorrectly

OBS

Check and correct

Broach body too small

VS

Use broach with larger body diameter

Broach condition

OBS

Check broach hardness and sharpening

Broken locking pin spring

OBS

Check and replace

Broken shear pins in pulley drive

OBS

Check and replace

Built up edge

MVA

Use coolant

Built up edge

OBS

Change tool geometry on tool material

Built up edge

MVA

Change tool geometry on tool material

Built up edge

OBS

Use coolant

Built up edge on drill corners

OBS

Polish flutes

Built up edge on drill corners

OBS

Change type of coolant used

Built up edge on drill corners

OBS

Use coolant

Built up edge on drill corners

OBS

Use oil hole drill

Burrs on broach teeth

OBS

Reburr broach after grinding

Change in workpiece residual stresses

VS

Stress relieve workpiece before milling

Changes in tensile and compressive forces

VS

One insert in depth of cut line area

Changes in tensile and compressive forces

VS

Reduce feed per insert

Changes in tensile and compressive forces

VS

Increase lead angle of cutter

Chasers set too far back of center

OBS

Advance all chasers of set gradually and equally until condition disappears

Chasers set too far back of center

OBS

Advance all chasers of set gradually and equally until condition disappears

Chasers set too far back of center

OBS

Advance all chasers of set gradually and equally until condition disappears

Chatter

VS

Reduce cutting speed

Chatter

VS

Reduce cutting speed

Chip clogging

OBS

Increase flow of cutting fluid

Chip size

OBS

Climb mill

Chip welding to cutting edges

OBS

Increase rake angle on chasers and grind cutting edges as smooth as possible

Chip welding to cutting edges

OBS

Increase length of chaser throat if permissible , especially for coarse pitch threads

Chip welding to cutting edges

OBS

Change cutting fluid being used and/ or increase flow

Chipbreaker too narrow or deep

VS

Increase chip breaker area

Chipbreaker too narrow or deep

OBS

Widen the Chip breaker

Chipped chasers

OBS

Regrind the chasers

Chipped or dull chasers

OBS

Regrind chasers

Chipped or dull chasers

OBS

Regrind chasers

Chips pack in bottom of hole

OBS

Begin cut at bottom of hole working up

Chips pack in bottom of hole

OBS

Use single thread cutter

Chucking does not center part

OBS

Use expanding mandrel on I.O instead of solid plug

Chucking pressures are too high

OBS

Use vaccum chuck

Chucking pressures are too high

OBS

Use wraparound type jaws to distribute chucking force

Chucking pressures are too high

OBS

On large diameter parts , use mechanical chucking to prevent vaccum distortion of precision tolerances

Clutches slipping

OBS

Check and replace

Coarse grains or foreign matter in wheel face

OBS

Dress out

Cold worked surfaces

OBS

Change previous processing

Collet does not open due to dirt and/ chips

OBS

Introduce mechanism to remove dirt and chips

Collet improperly adjusted

OBS

Check and correct

Collet too tight

OBS

Redesign Collet

Component hardness high

PC

Use cutting fluid , making sure it reaches drill point

Component hardness high

PC

Improve drill material

Component hardness high

PC

Improve cutting fluid being used

Crater wear

VS

Increase coolant flow rate

Crooked hole in workpiece

OBS

Check previous operations

Cutter design

VS

Use multifaceted " master cut" style cutters

Cutter geometry

VS

Change helix angle

Cutter geometry

VS

Change cutter design

Cutter size and forces

VS

Use single thread cutter ; do not use tool compensation on dull tool

Cutting conditions

VS

Change feed rate

Cutting conditions

VS

Use faster cutting speeds and/ feed rates

Cutting conditions

VS

Have tool to depth of cut line on tool

Cutting conditions

VS

Reduce feed rate

Cutting conditions

VS

Use cutting fluid

Cutting conditions

VS

Control chip geometry

Cutting conditions

VS

Use more shock resistant grade of tool material

Cutting conditions

VS

Change cutting speed

Cutting conditions

VS

Use vibration dampers in tool or tailstock

Cutting conditions

VS

Use positive rake tools

Cutting conditions

VS

Use stronger tool geometries, including thicker inserts

Cutting conditions

VS

Increase tool lead angle

Cutting conditions

VS

Use coated inserts , particularly those with aluminium oxide, titanium carbide or titanium nitride

Cutting conditions

VS

Reduce feed rate and / depth of cut

Cutting conditions

VS

Reduce depth of cut

Cutting conditions

VS

Use ceramic inserts

Cutting edge too sharp

OBS

Chamfer cutting edge

Cutting forces

VS

Increase cutting speed

Cutting forces

VS

Reduce feed rate or depth of cut

Cutting forces

VS

Reduce cutting speed

Cutting forces

VS

Reduce cutting speed and/ feed rate

Cutting forces deflect part

OBS

Support part

Cutting forces deflect part

OBS

Depth of cut

Cutting forces deflect part

OBS

Reduce feed

Cutting forces deflect part

OBS

Change tool geometry

Cutting forces high

VS

Decrease cutting speed

Cutting forces high

VS

Reduce cutting speed