How to Prevent Cutting Tool Failures

Cutting tools — whether drill bits, reamers or hole cutters — play a central role in ensuring accuracy and consistency in fabrication and maintenance operations. Yet, there can still be failures. Not from poor tool quality, but from improper use or lack of maintenance or oversight during operation. Following a structured approach before, during and after use can dramatically extend tool life and prevent accidents.

1. Before Use

Proper preparation is the foundation of tool performance and longevity.

• Inspect the drill motor and cords. Check for frays, loose connections or damaged components. Ensure the chuck is secure and balanced. Tighten each hole on keyed chucks and use both hands for keyless types.
• Select the right tool for the job. Choose the correct cutting tool based on the material. For example, Super Primalloy® Maintenance Length bits are versatile and specific for maintenance drilling. Using the wrong bit can lead to premature wear or breakage.
• Use coolants and lubricants. These reduce heat, minimize friction and extend tool life. Even a basic lubricant can make a difference when drilling through metal.
• Secure your material. Always clamp or vise smaller pieces to prevent spinning or twisting. Never hold material by hand while drilling.

Good habits during operation prevent small mistakes from becoming costly failures.

• Monitor chip removal. Consistent chip flow indicates proper speed and feed. If chips clog or discolor, reduce speed or apply lubricant.
• Ease pressure at breakthrough. When the bit is about to exit the material, ease up on pressure to avoid binding and tip breakage.
• Avoid forcing a dull bit. Stop and replace dull bits immediately — forcing them overheats and damages the edge and can lead to injury from slipping or drill bit breakage.
• Pause and check temperature. Overheating causes bluing and loss of hardness. A brief pause allows both the tool and material to cool.
• Don’t use drill bits to enlarge holes. Regular bits are not designed for reaming; use step drills or reamers instead. Doing otherwise risks chipping or breaking the bit.

What you do after cutting is just as important as setup.

• Clean and inspect the tool. Remove chips and oil residue, and check for signs of wear, cracks or dull edges before storage.
• Store tools properly. Keep bits and reamers organized in their indexes or protective cases to prevent edge damage.
• Log tool performance. Tracking which tools perform best on certain materials helps refine future selection and prevent repeated failures.
• Replace worn parts promptly. A small investment in maintenance prevents damage to your workpiece or equipment.
• Review safety practices. Each session is an opportunity to reinforce what worked and what didn’t — ensuring safer and more efficient operations next time.

Cutting tool failures are almost always preventable. With proper inspection before use, attentive monitoring during operation and disciplined care afterward, you’ll extend tool life, improve accuracy and reduce downtime. Remember: Kimball Midwest sales representatives can help you prevent these failures. Reach out to your rep to learn more. If you do not already have a rep, we can help you