Broken Tool Removal: A Modern Solution for Saving Expensive Workpieces

Tool breakage during machining is a situation familiar to every manufacturing plant and repair workshop. It's particularly frustrating when a drill bit, tap, or milling cutter breaks inside an expensive workpiece or nearly finished part. Traditional removal methods often damage the workpiece itself, rendering it unsuitable for further use.

BAS-AGRO LLC offers a professional solution to this problem — broken tool removal using electrical discharge machining (EDM).

Video of broken tool removal (burning out broken tool)

Why Do Tools Break and What to Do Next?

There are many reasons for cutting tool breakage: excessive load, wear, incorrectly selected cutting parameters, cracks in the tool material. The result is the same — part of a drill bit, tap, or other tool gets stuck in the part, and removing it by conventional methods is impossible.

If the workpiece is inexpensive, it's often written off. But when dealing with:

• large complex-shaped parts
• workpieces made from expensive alloy steels
• parts with multi-stage preliminary processing
• unique or hard-to-source agricultural machinery components

...losing such a workpiece means significant financial losses and production delays.

Electrical Discharge Machining — A Rescue Technology

An EDM machine operates on a principle fundamentally different from mechanical machining. Material removal occurs through electrical discharges between the electrode-tool and the workpiece in a dielectric fluid medium. Each discharge "burns out" a microscopic particle of material.

Key Advantages of the Method:

Working with super-hard materials. An EDM machine can process any electrically conductive materials regardless of their hardness. Even if the broken tool is made from carbide materials or high-speed steel, this creates no obstacles for removal.

No mechanical load. Since cutting occurs without contact, the risk of additional workpiece damage is eliminated. There are no vibrations, impact loads, or deformations.

High precision. The technology allows removing tool remnants with minimal impact on hole geometry and adjacent surfaces. After removal, part machining can continue.

Economic feasibility. The cost of broken tool removal service is significantly lower than the cost of a new workpiece, especially when dealing with complex parts for agricultural machinery.

When to Use This Service

Broken tool removal service is particularly relevant for:

• Repair workshops servicing agricultural machinery
• Manufacturing plants with serial production
• Parts manufacturers where every component is worth its weight in gold
• Agricultural enterprises with their own repair facilities

If the workpiece cost exceeds several thousand hryvnias, and broken tool removal costs significantly less — the decision is obvious.

BAS-AGRO LLC: More Than Just Tool Removal

BAS-AGRO company specializes in manufacturing spare parts for agricultural machinery. Having EDM equipment allows not only producing complex parts but also providing services for saving expensive workpieces.

Why Choose BAS-AGRO:

• Experience in the agricultural industry — we understand the specifics of parts for combines, tractors, sprayers, and other equipment
• Modern equipment — EDM machines capable of working with parts of various sizes and complexity
• Comprehensive approach — if further processing or manufacturing of a similar part is needed after tool removal, we can provide it
• In-house spare parts production — wide catalog of ready solutions for agricultural machinery at bas.ua

How the Process Works

1. Situation assessment. Specialists determine the location of the broken tool, its type, and workpiece material.
2. Preparation. The part is installed on the EDM machine, optimal processing parameters are selected.
3. Removal. The process of burning out tool remnants can take from several minutes to several hours depending on diameter and depth of penetration.
4. Quality control. After completion, removal cleanliness and workpiece condition are verified.
5. Delivery to customer. The part is ready for further processing or use.

Practical Tips for Minimizing Breakage

While broken tool removal service is effective, it's better to prevent such situations:

• Use quality tools from verified manufacturers
• Monitor cutting edge wear and replace tools timely
• Follow recommended cutting parameters
• Ensure proper cooling and lubrication during machining
• Don't overload the tool, especially when working with hard materials

Breaking an expensive tool in a workpiece is not a death sentence. Modern EDM technologies allow effectively solving this problem without losing an expensive part. BAS-AGRO LLC offers professional broken tool removal service, combining years of experience in agricultural machinery spare parts manufacturing with high-tech equipment capabilities.

Need a quality spare part for a combine, tractor, or other agricultural machinery? Tool broke in an expensive workpiece? Contact BAS-AGRO — we'll find a solution for any production challenge.

Spare parts and services catalog: bas.ua