title = "Troubleshooting Common Machining Problems"

content = """
Even well-planned machining operations encounter problems. Systematic
troubleshooting identifies root causes and implements effective solutions.

**Poor Surface Finish:**
- *Causes:* Dull tool, incorrect speeds/feeds, excessive tool deflection,
vibration/chatter, built-up edge.
- *Solutions:* Replace or resharpen tool, reduce feed rate, increase spindle
speed, use shorter/rigid tool setup, apply appropriate coolant, ensure climb
milling direction.

**Dimensional Inaccuracy:**
- *Causes:* Tool wear, thermal expansion, fixture deflection, incorrect offsets,
programming errors, machine positioning errors.
- *Solutions:* Implement tool wear compensation, allow thermal warm-up, verify
fixture rigidity, double-check offsets, verify program coordinates, calibrate
machine or apply compensation.

**Premature Tool Wear or Breakage:**
- *Causes:* Excessive speeds/feeds, interrupted cuts, hard spots in material,
incorrect tool geometry, inadequate coolant, machine vibration.
- *Solutions:* Reduce parameters, use stronger tool geometry, verify material
consistency, improve coolant delivery, check machine condition (spindle bearing,
gib adjustment).

**Chatter and Vibration:**
- *Causes:* Tool overhang, thin-walled workpiece, incorrect speeds creating
resonance, worn machine components, improper tool path.
- *Solutions:* Reduce overhang, increase wall support, adjust spindle speed
(±10-20% to escape resonance), check spindle runout, use variable pitch tools,
apply trochoidal paths instead of full-width slotting.

**Chip Control Problems:**
- *Causes:* Incorrect feed rate, wrong tool geometry, stringy material (aluminum,
low-carbon steel), insufficient coolant, deep hole drilling without peck cycles.
- *Solutions:* Adjust feed for proper chip thickness, use chipbreaker inserts,
apply high-pressure coolant, implement peck drilling cycles, add chip conveyors.

**Burrs on Exit Edges:**
- *Causes:* Material tearing on through-hole exits, side-milling exits, incorrect
feeds on exit.
- *Solutions:* Reduce feed rate on exit, use back chamfer tools, program exit
strategies (roll-off rather than straight exit), add deburring operations.

**Workpiece Movement:**
- *Causes:* Insufficient clamping force, vibration loosening clamps, cutting
forces exceeding fixture capacity, thermal expansion causing stress.
- *Solutions:* Increase clamping (without distortion), check fixture integrity,
reduce cutting forces, use more rigid workholding, verify part locating.

**Systematic Approach:**
Document problems and solutions to build organizational knowledge. Change one
variable at a time to isolate causes. Use structured problem-solving (5-Why
analysis, fishbone diagrams) for recurring issues.
"""

version = "0.0.1"
