In order to achieve better quality and the longest possible tool life in the cutting process, we need to check the inserts after machining, summarize the causes of different forms of insert wear and find solutions, which are the basis for successful milling.
Flank wear 1
Rapid wear results in poor surface quality or out-of-tolerance tolerances.
cause
- The cutting speed is too high
- Lack of abrasion resistance
- The feed fz is too low
solution
- Reduced cutting speed (VC)
- Choose a material with higher abrasion resistance
- Increasing Feed (fz)
Flank wear 2
Excessive wear results in short tool life.
cause
- vibration
- Chip re-cutting
- Burrs form on the part
- Poor surface quality
- Generate heat
solution
- Increasing Feed (fz)
- Climb milling is adopted
- Compressed air is used for effective chip evacuation
- Check the recommended cutting data
Flank wear 3
Uneven wear leads to damage to sharp corners.
cause
- Tool runout
- vibration
- Short tool life
- Poor surface quality
- Loud noise
- The radial force is too high
solution
- Reduce the runout to less than 0.02 mm
- Check the chuck and collet
- Minimizes tool protrusion
- Use fewer teeth for cutting
- Choose a larger tool diameter
- For solid carbide end mills and exchangeable head mills, select geometries with a larger helix angle (GP ≥45°)
- Splits the axial depth of cut (AP) into multiple passes
- Reduced Feed (fz)
- Reduced cutting speed (VC)
- High-speed machining requires shallow passes
- Improved tool and workpiece set-up
Crescent craters are worn out
Excessive wear results in a decrease in cutting edge strength. Poor surface quality due to broken cutting edges.
cause
Diffusion wear due to high rake cutting temperature
solution
- Choose an alumina coating material
- Positive angle insert geometry is selected
- Lower the speed to get a lower temperature, and then there is a lower feed
Plastic deformation
Plastic deformation, collapse of the cutting edge, or denting of the flank flank, resulting in poor chip control, poor surface quality, and insert breakage.
cause
Cutting temperature and pressure are too high
solution
- Choose a material that is more resistant to abrasion (harder).
- Reduced cutting speed (VC)
- Reduced Feed (fz)
Collapse blade 1
The part of the cutting edge that is not involved in the cutting is damaged by chip hammering. Damage to the front and support surfaces of the insert, resulting in poor surface texture and excessive flank wear.
cause
The chips are crushed by the action of the cutting edge
solution
- Choose a grade with higher toughness
- Choose inserts with stronger cutting edges
- Increase cutting speed vc
- Select the positive geometry
- The feed is lowered at the beginning of cutting
- Improved stability
Collapse Blade 2
A small percentage of cutting edge cracks (chipping) resulting in poor surface quality and excessive flank wear.
cause
- The toughness of the material is too low
- The insert geometry is too weak
- Built-up edge is produced
solution
- Choose a grade with higher toughness
- Choose inserts with a stronger geometry
- Increase the cutting speed vc, or select a positive geometry
- The feed is lowered at the beginning of cutting
Groove wear
Groove wear leads to poor surface quality and the risk of cutting edge breakage.
cause
- Work-hardened materials
- Epidermis and oxide scale
solution
- Reduced cutting speed (VC)
- Choose a grade with higher toughness
- Use a stronger geometry
- Use a cutting angle closer to 45°
- Use a round blade to ensure the best results
- Wear and tear are delayed using variable AP technology
Thermal cracking
Small cracks perpendicular to the cutting edge due to temperature changes lead to chipping and poor surface quality.
cause
- Intermittent processing
- Variable cutting fluid supply
solution
- Choose materials that are tougher and more resistant to thermal shock
- Cutting fluid should be used in sufficient quantities or at all
Built-up edge 1
Built-up edge causes poor surface quality and causes the cutting edge to shatter when it falls off.
cause
- The temperature in the cutting area is too low
- Materials are very viscous, such as mild steel, stainless steel, and aluminum
solution
- Increase cutting speed vc
- Switch to a more suitable insert geometry
Built-up edge 2
The workpiece material is welded to the cutting edge.
cause
- Low cutting speed vc
- Low feed fz
- Front Angle Cutting Tank Type
- Poor surface quality
solution
- Increase cutting speed vc
- Increasing Feed (fz)
- Select the positive geometry
- Use oil mist or cutting fluid