--- title: How to best manage chips – causes, and solutions description: "What are the causes and solutions in short chip management?\nWhat are the causes and solutions in long chip management?\nRead the in-depth analysis below." image: https://blog.sautool.com/hubfs/trucioli.png --- [![logo-sau-blu@2x](https://blog.sautool.com/hubfs/logo-sau-blu@2x.svg)](https://blog.sautool.com/blog?hsLang=en) [GO TO SAUTOOL.COM](https://www.sautool.com/en) [Contact us](https://sautool.com/en/contact-us) News # How to best manage chips – causes, and solutions What are the causes and solutions in short chip management? What are the causes and solutions in long chip management? Read the in-depth analysis below. [SAU Team](https://blog.sautool.com/en/author/sau-team) Feb 11, 2026 --- This guide was born from the desire to be able to solve the biggest problems in turning processes, going against the operators in the sector who find themselves taken aback by some unpleasant inconveniences. Keep reading. ## Chip Management - Cause/Solution ### Long chip control Long tangled chips that wrap around the tool or workpiece. Generally due to low feed values and low and/or shallow cutting depths.   ![LONG CHIP](https://blog.sautool.com/hs-fs/hubfs/TRUCIOLO-LUNGO.png?width=200&height=141&name=TRUCIOLO-LUNGO.png) #### *Cause* - Progress too low for the chosen geometry #### *Solution* - Increase progress - Choose an insert geometry with better chip control characteristics - Use a tool with precision coolant --- #### *Cause* - Cutting depth too low for the chosen geometry #### *Solution* - Increase cutting depth, or choose a geometry with better chip control characteristics --- #### *Cause* - Nose radius is too large #### *Solution* - Select a smaller nose radius --- #### *Cause* - Recording angle not suitable #### *Solution* - Choose an attachment with the widest possible recording angle (angle of attachment). KAPR = 90° (PSIR = 0°) --- ### Short chip control Very short chips, often glued together, due to difficult chip breakage. Difficult chip breakage often reduces tool life or results in insert breakage, due to the high chip load on the cutting edge. ## **![TRUCIOLO-CORTO](https://blog.sautool.com/hs-fs/hubfs/TRUCIOLO-CORTO.png?width=200&height=187&name=TRUCIOLO-CORTO.png)** #### *Cause* - Progress too high for the chosen geometry #### *Solution* - Choose a geometry designed for higher feeds, preferably a single-sided insert - Reduce progress --- #### *Cause* - Recording angle not suitable #### *Solution* - Choose an attachment with the smallest possible recording angle (angle of attachment). KAPR = 45°–75° (PSIR 45–15°) --- #### *Cause* - Nose radius is too small #### *Solution* - Select a bigger nose radius --- ### **Surface finish** The surface has an irregular appearance, both to the touch and to the eye, and does not conform to the specified tolerances. ![finitura-superfice-3](https://blog.sautool.com/hs-fs/hubfs/finitura-superfice-3.png?width=300&height=179&name=finitura-superfice-3.png) #### *Cause* - The chips break against the component leaving marks on the finished surface #### *Solution* - Select a geometry which guides the chips away from the component - Change entering angle - Reduce depth of cut - Select a positive tool system with a neutral angle of inclination --- #### *Cause* - Irregular surface caused by excessive notch wear of the cutting edge #### *Solution* - Select a grade with better resistance to oxidation wear, for example Cermet - Reduce the cutting speed --- #### *Cause* - Feed is too high, in combination with a nose radius that is too small, a rough surface is generated #### *Solution* - Select a wiper insert or a larger nose radius - Reduce feed --- ### Burr formation Burr formation on the workpiece when entering or exit of the workpiece. ![formazione-bave-2](https://blog.sautool.com/hs-fs/hubfs/formazione-bave-2.png?width=300&height=179&name=formazione-bave-2.png) #### *Cause* - The cutting edge is not sharp enough - The feed is too low for the edge roundness #### *Solution* - Use insert with sharp edges, PVD coated inserts or ground inserts at small feed rates, < 0.1 mm/rev --- #### *Cause* - Notch wear at depth of cut, or chipping #### *Solution* - Use a holder with a small entering angle --- #### *Cause* - Burr formation at the end or start of cut #### *Solution* - End or start the cut with a chamfer or a radius when exiting/entering the workpiece --- ### Vibrations High radial cutting forces due to vibrations or marks produced by vibrations caused by tools or tool assembly. Typical problems of in-house machining with boring bars. ![vibrazioni-3](https://blog.sautool.com/hs-fs/hubfs/vibrazioni-3.png?width=300&height=179&name=vibrazioni-3.png) #### *Cause* - Unsuitable entering angle #### *Solution* - Select a larger entering angle (lead angle). KAPR = 90° (PSIR = 0°) --- #### *Cause* - Nose radius is too large #### *Solution* - Select a smaller nose radius --- #### *Cause* - Unsuitable edge rounding, or negative chamfer #### *Solution* - Select a grade with a thin coating, or an uncoated grade --- #### *Cause* - Excessive flank wear on the cutting edge #### *Solution* - Select a more wear resistant grade or reduce speed --- ### Vibration High tangential cutting forces. ![FORZE-TANGENZIALI](https://blog.sautool.com/hs-fs/hubfs/FORZE-TANGENZIALI.png?width=300&height=314&name=FORZE-TANGENZIALI.png) #### *Cause* - Insert geometry creating high cutting forces - Chip breaking is too hard, producing high cutting forces #### *Solution* - Select a positive insert geometry - Reduce the feed or select a geometry for higher feeds --- #### *Cause* - Cutting forces vary or are too low due to small depth of cut #### *Solution* - Increase the depth of cut to make the insert cut --- #### *Cause* - Tool is incorrectly positioned #### *Solution* - Check the centre height --- #### *Cause* - Instability in the tool due to long overhang #### *Solution* - Reduce the overhang - Use the largest possible bar diameter - Use Anti-vibration tool or a carbide bar --- #### *Cause* - Unstable clamping leads to insufficient rigidity #### *Solution* - Extend the clamping length of the boring bar --- ### Insert wear To work with optimized cutting data, obtain the best possible quality components and safeguard tool life, always check the insert/cutter after machining. For successful turning, refer to this list of causes and solutions of various forms of insert wear.   #### Flank wear Preferable wear type in every application. Offers predictable and stable tool life. ![USURA-FIANCO](https://blog.sautool.com/hs-fs/hubfs/USURA-FIANCO.png?width=200&height=159&name=USURA-FIANCO.png) #### *Cause* - Cutting speed too high - Too tough grade - Insufficient wear resistance - Hard inclusions in workpiece material #### *Solution* - Reduce cutting speed - Select a more adequate quality in terms of toughness or wear resistance --- #### Notch wear ![USURA-AD-INTAGLIO](https://blog.sautool.com/hs-fs/hubfs/USURA-AD-INTAGLIO.png?width=200&height=159&name=USURA-AD-INTAGLIO.png) #### *Cause* - Sticky and/or work-hardening materials - Use a ~90° entering angle (~0° lead angle) - Geometry is too negative #### *Solution* - Select a sharper edge - Decrease entering angle - Vary depth of cut --- #### Crater wear ![USURA-CRATERIZZAZIONE](https://blog.sautool.com/hs-fs/hubfs/USURA-CRATERIZZAZIONE.png?width=200&height=159&name=USURA-CRATERIZZAZIONE.png) #### *Cause* - Too high cutting speed and/or feed - Chip breaker too narrow - Chemical dissolution or abrasive wear - Wear resistance too low #### *Solution* - Reduce cutting speed or feed - Select a more wear resistant grade - Select a more open/positive geometry --- #### Plastic deformation Depression Impression ![USURA-DEFORMAZIONE-PLASTICA](https://blog.sautool.com/hs-fs/hubfs/USURA-DEFORMAZIONE-PLASTICA.png?width=200&height=159&name=USURA-DEFORMAZIONE-PLASTICA.png) #### *Cause* - High heat load and pressure, cutting temperature too high - Grade too tough/soft - Lack of coolant supply #### *Solution* - Reduce heat and pressure load by reducing cutting speed and/or feed - If edge depression, reduce feed first - If flank depression, reduce speed first - Select a more wear/heat resistant grade - Select a more open/positive geometry - Improve coolant supply --- #### Built-up edge (B.U.E) ![USURA-TAGLIENTE-RIPORTO](https://blog.sautool.com/hs-fs/hubfs/USURA-TAGLIENTE-RIPORTO.png?width=200&height=159&name=USURA-TAGLIENTE-RIPORTO.png) #### *Cause* - Too low cutting temperature - Sticky/smeary material - Geometry too negative - Coating too thick #### *Solution* - Increase cutting temperature by increasing speed - Select a PVD-coated grade (less T. D. R. on PVD-coatings) - Select a more positive geometry --- #### Flaking ![USURA-SFALDAMENTO](https://blog.sautool.com/hs-fs/hubfs/USURA-SFALDAMENTO.png?width=200&height=159&name=USURA-SFALDAMENTO.png) #### *Cause* - Smeary material - Cutting speed too low - Intermittent machining with coolant - Coating too thick #### *Solution* - Increase cutting speed - Turn off coolant - Select a grade with thinner coating and better edge line security (PVD) --- #### Chipping on edge ![USURA-SCHEGGIATURA](https://blog.sautool.com/hs-fs/hubfs/USURA-SCHEGGIATURA.png?width=200&height=159&name=USURA-SCHEGGIATURA.png) #### *Cause* - Unstable conditions - Grade too hard/brittle - Coating too thick (CVD, leading to edge line flaking) #### *Solution* - Make the machine conditions more stable - Select a tougher grade - Select a stronger geometry - Select grade with thinner coating (PVD) --- #### Thermal cracks ![USURA-MICROFESSURAZIONI](https://blog.sautool.com/hs-fs/hubfs/USURA-MICROFESSURAZIONI.png?width=200&height=159&name=USURA-MICROFESSURAZIONI.png) #### *Cause* - Varying cutting edge temperatures - Intermittent cuts and coolant - Grade is sensitive to heat shock variations - Use of grade with thicker coating (CVD) #### *Solution* - Switch off coolant or apply coolant copiously to obtain an even temperature level - Decrease cutting speed - Select grade with thinner coating (PVD) --- #### Breakage ![ROTTURA-TAGLIENTE](https://blog.sautool.com/hs-fs/hubfs/ROTTURA-TAGLIENTE.png?width=200&height=159&name=ROTTURA-TAGLIENTE.png) #### *Cause* - Excessive wear - Wrong choice of grade (too tough/hard) - Wrong cutting data #### *Solution* - Run shorter (time in cut) operations: check how wear begins and the dominant wear type - Change cutting data - Select a more suitable insert grade/geometry --- #### Slice fracture - ceramics ![USURA-SFALDAMENTO-CERAMICA](https://blog.sautool.com/hs-fs/hubfs/USURA-SFALDAMENTO-CERAMICA.png?width=200&height=159&name=USURA-SFALDAMENTO-CERAMICA.png) #### *Cause* - Excessive tool pressure #### *Solution* - Reduce feed - Select a tougher grade - Select an insert with a smaller chamfer, or use another geometry to change cutting force direction --- #### Chipping outside the cutting zone ![USURA-SCHEGGIATURA-EST-TAGLIO](https://blog.sautool.com/hs-fs/hubfs/USURA-SCHEGGIATURA-EST-TAGLIO.png?width=200&height=159&name=USURA-SCHEGGIATURA-EST-TAGLIO.png) #### *Cause* - Chip jamming because of facing towards shoulder - The chips are deflected against the cutting edge - Not optimized feed or feed direction #### *Solution* - Change operation path (to avoid facing towards shoulder) - Change feed - Select a PVD-coated grade - Select an insert geometry that alters the chip flow --- ## **Conclusions** Sau with its forty years of experience can solve your problems and provide you with considerable technical support. Thanks to all this and the advanced technologies that enable its continuous growth and the possibility of offering solutions tailored to every need, it makes SAU the ideal partner for those who want to achieve excellent results in every situation. To learn more about how to best manage your chip and how Sau can improve your manufacturing processes, [contact us today](https://sautool.com/en/contact-us). Sau Team *SAU - Quality Tools Engineering since 1982.*   [News](https://blog.sautool.com/en/tag/news) [Turning](https://blog.sautool.com/en/tag/turning) ## Similar posts News ### [Automatic vertical warehouse integrated with management system | THE BOX](https://blog.sautool.com/en/automatic-vertical-wareouse-integrated-with-management-system-the-box?hsLang=en) If you are looking for a warehouse to store products integrated with your management system, discover now THE BOX: the compact vertical automatic... 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