I had a 1/2" carbide tool break right at the clamping screw recently in a nice cat 40 tool holder. It ran long enough to develop a ring of carbide chips that have embedded themselves into the tool holder. I cant hammer them out with a punch . Any ideas? Any chemical removal method that wont damage the holder?
Perhaps you can find a diamond coated burr, set up the burr in a grinder in a lathe toolpost, chuck the toolholder and grind a bit of a relief groove in the affected zone. I'm assuming that there would be sufficient bore in good condition on either side of the setscrew hole to still locate the tools accurately. However, it might be possible that tightening the setscrew in this kind of relieved bore would bend the endmill a little bit, which means it is most likely not useful for anything except a single flute insert mill where the runout doesn't matter.
First you get good, then you get fast. Then grouchiness sets in.
(Note: The opinions expressed in this post are my own and are not necessarily those of CNCzone and its management)