Knowledge Base

Breakage Prevention Series

Technical deep dives backed by testing data. Each article solves a real machining problem.

Re-Gashing DIY: Can You Save a Broken Tool?

Is re-gashing a broken end mill worth the effort? We break down DIY equipment costs, technique, and when to use a professional sharpening service.

Compare flood coolant, MQL, air blast, and cryogenic cooling for CNC machining. Learn why MQL often outperforms flood and how to choose correctly.

A data-driven cost-per-part analysis proving that premium carbide tooling often costs less than budget alternatives when you factor in downtime.

Identify the 5 critical warning signs of imminent CNC tool failure: surface finish changes, force spikes, chip shifts, acoustic signals, and drift.

Learn how micro-gashing techniques for sub-1mm tools meet the extreme demands of FDA-regulated medical device manufacturing and micromachining.

Explore how 2026 AI-native CAM systems use real-time toolpath analysis and cutting load prediction to prevent costly spindle crashes automatically.

Master chip thinning calculations to optimize feed rates and dramatically extend tool life. Includes formulas, charts, and real-world examples.

We tested 5 top-rated 'unbreakable' drill bit sets head-to-head in steel, stainless, and cast iron. See the hole counts and the clear winner.

Learn proven strategies to prevent tool breakage when machining Titanium 6Al-4V. Covers chip loads, deflection control, and heat management.

Discover how gash angle and chip evacuation geometry directly cause end mill failure. Learn the geometry secrets that extend tool life by 2-3x.