Lexington Cutter has a put together a short checklist of the five most common problems for addressing reaming problems. If these don't fix your particular problem, get in contact with us and we'll send one of our application specialist in to give you a hand.
1) Poor Finish
Possible Causes – Unequal chamfers, Incorrect margins, Excessive spindle runout, Chatter
Possible Solutions – Regrind reamer with equal chamfer angle. Regrind reamer with narrow margins for reaming lower tensile materials. Increase reamer back taper (will lose size faster). Reduce speed and increase feed rate. Use power feed unless material is hard. Use right or left spiral fluted reamer. Grind secondary lead angle immediately back of 45° chamfer.
Possible Causes – Unequal chamfers, Incorrect margins, Excessive spindle runout, Chatter
Possible Solutions – Regrind reamer with equal chamfer angle. Regrind reamer with narrow margins for reaming lower tensile materials. Increase reamer back taper (will lose size faster). Reduce speed and increase feed rate. Use power feed unless material is hard. Use right or left spiral fluted reamer. Grind secondary lead angle immediately back of 45° chamfer.
2) Oversize Hole - Taper Hole - Bell Mouth Hole - Poor Finish
Possible Causes – Misalignment, Insufficient, cutting action
Possible Solutions – Use bushing – .0002″/.0003″ over reamer diameter. If hole location varies, use floating reamer holder. Increase reamer back taper (will lose size faster). Specify reamer with positive radial rake to reduce cutting pressure – may produce slightly larger diameter holes.
Possible Causes – Misalignment, Insufficient, cutting action
Possible Solutions – Use bushing – .0002″/.0003″ over reamer diameter. If hole location varies, use floating reamer holder. Increase reamer back taper (will lose size faster). Specify reamer with positive radial rake to reduce cutting pressure – may produce slightly larger diameter holes.
3) Excessive Tool Wear
Possible Causes – Insufficient stock for removal, Excessive reaming pressure, Misalignment
Possible Solutions – Decrease previous operation drill size to allow more material for removal by reamer – leave about 3% of hole diameter for cast iron and more stock for non-ferrous materials. Increase feed rate. Reduce stock to be removed by increasing previous operation drill size – leave about 3% of the hole diameter. See Problem #2
Possible Causes – Insufficient stock for removal, Excessive reaming pressure, Misalignment
Possible Solutions – Decrease previous operation drill size to allow more material for removal by reamer – leave about 3% of hole diameter for cast iron and more stock for non-ferrous materials. Increase feed rate. Reduce stock to be removed by increasing previous operation drill size – leave about 3% of the hole diameter. See Problem #2
4) Crooked Holes
Possible Causes – Not drilled straight
Possible Solutions – Correct previous drilling operation – reamer will follow the drilled hole. Increase reamer attack angle (chamfer) to 120°/180° included angle.
Possible Causes – Not drilled straight
Possible Solutions – Correct previous drilling operation – reamer will follow the drilled hole. Increase reamer attack angle (chamfer) to 120°/180° included angle.
5) Tool Breakage
Possible Causes – Excessive reaming pressure, Misalignment
Possible Solutions – Reduce stock to be removed – See Problem #3 – See Problem #2
Possible Causes – Excessive reaming pressure, Misalignment
Possible Solutions – Reduce stock to be removed – See Problem #3 – See Problem #2
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