 |
| Tool damage form |
Causes |
Countermeasures |
Flank wear
|
 |
- Tool grade is too soft.
- Cutting speed is too high.
- Flank angle is too small.
- Feed rate is extremely low.
|
- Tool grade with high wear resistance.
- Lower cutting speed.
- Increase flank angle.
- Increase feed rate.
|
| Crater wear |
 |
- Tool grade is too soft.
- Cutting speed is too high.
- Feed rate is too high.
|
- Tool grade with high wear resistance.
- Lower cutting speed.
- Lower feed rate.
|
| Chipping |
 |
- Tool grade is too hard.
- Feed rate is too high.
- Lack of cutting edge strength.
- Lack of shank,holder rigidity.
|
- Tool grade with high toughness.
- Lower feed rate.
- Increase honing.(Round honing is to be changed to chamfer honing)
- Use larger shank size.
|
| Fracturing |
 |
- Tool grade is too hard.
- Feed rate is too high.
- Lack of cutting edge strength.
- Lack of shank or holder rigidity
|
- Tool grade with high toughness.
- Lower feed rate.
- Increase honing.(Round honing is to be changed to chamfer honing)
- Use larger shanksize.
|
| Plastic deformation |
 |
- Tool grade is too soft.
- Cutting speed is too high.
- Depth of cut and feed rate are too large.
- Cutting temperature is high.
|
- Tool grade with high wear resistance.
- Lower cutting speed.
- Decrease depth of cut and feed rate.
- Tool grade with high thermal conductivity.
|
Welding
|
 |
- Cutting speed is low.
- Poor sharpness.
- Unsuitable grade.
|
- Increase cutting speed (For Din Ck45,ANSI1045,Cutting speed >=80m/min))
- Increase rake angle.
- Tool grade with low affinity
(Coated grade,cermet grade)
|
| Thermal cracks |
 |
- Expansion or shrinkage due to cutting heat.
- Tool grade is too hard.
*Especially in milling.
|
- Dry cutting.
(for wet cutting,flood workpiece with cutting fluid)
- Tool grade with high toughness.
|
| Notching |
 |
- Hard surfaces such as uncut surface, chilled parts and machining hardened
layers.
- Friction caused by jagged shape chips.
(Caused by small vibrations)
|
- Tool grade with high wear resistance.
- Increase rake angle to improve sharpness.
|
| Flaking |
 |
- Cutting resistance is too high.
- Cutting edge welding and adhesion.
- Poor chip disposal.
|
- Increase rake angle to improve sharpness.
- Enlarge chip pocket.
|
Flank wear
Fracture
* Damage for polycrystallines |
 |
- Damage due to the lack of strength of a curved cutting edge.
|
- Increase honing.
- Tool grade with high toughness.
|
Crater wear fracture
*This type of fracture is
super high-pressure
sintering |
 |
- Tool grade is too soft
- Cutting resistance is too high and causes high cutting heat.
|
- Decrease honing.
- Tool grade with high wear resistance.
|
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