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Groove-Turn & Parting
ISO Turn
Threading
Milling
Hole making
Products Main Page
>
Insert Wear Problems and Solutions
>
Milling Inserts Wear Problems and Solutions
Milling Inserts Wear Problems and Solutions
MILLING - INDEXABLE INSERTS
MILLING -
SOLID CARBIDE AND
MULTI-MASTER
Type of Wear
×
Flank Wear
Flank Wear
Cause
High cutting speed
Low wear resistance carbide grade
Remedy
Reduce cutting speed
Use a more wear- resistant cutting tool material grade
Select a more wear resistant grade
For work-hardening materials, select a smaller entry angle
Reduce the cutting speed when machining heat resistant materials
×
Crater Wear
Crater Wear
Cause
Excessive cutting temperatures and pressures on the top of the insert
Remedy
Reduce cutting speed
Reduce feed
Use a tool with more positive geometry
Use a harder material grade
Select a more wear resistant grade
Select a more positive insert geometry
Reduce the cutting speed or reduce the feed rate to lower the temperature
Use higher coolant flow and pressure, consider High pressure coolant
×
Plastic Deformation
Plastic Deformation
Cause
Cutting temperature is too high
Remedy
Reduce cutting speed
Use a harder material grade
Significantly increase coolant supply
×
Notch Wear
Notch Wear
Cause
Cutting speed is too high, or insufficient insert wear resistance of the carbide grade
Remedy
Use more wear resistant tool material grade
Reduce cutting speed
Vary cutting depth
Use insert with a reinforced cutting edge geometry
For work-hardening materials, select a smaller entry angle
Reduce the cutting speed when machining heat resistant materials
×
Thermal Cracking
Thermal Cracking
Cause
Excessive variations in surface temperature, intermittent machining, or variations in coolant supply
Remedy
Reduce cutting speed
Use tougher cutting tool material grade
Significantly increase coolant supply or turn it off
Eliminate the use of coolant whenever possible
×
Edge Fracture
Edge Fracture
Cause
Caused by excessive insert wear before indexing the insert
The grade and geometry could be too weak for the applications
Excessive load on the insert
Built-up edge has been formed on the insert
Remedy
Use inserts with larger corner radius / chamfer, preferrably single-sided
Use cutters of chatter-free geometry
Use a tougher cutting tool material grade
Reduce feed
Apply vibration-dampening toolholders
×
Built-up Edge
Built-up Edge
Cause
Cutting zone temperature is too low
Negative cutting geometry
Machining of very sticky materials such as low-carbon steel, stainless steels, and aluminum
Remedy
Increase cutting speed
Use cutters with more positive rake angle and sharper cutting edge
Significantly increase coolant supply
Use inserts, produced from a tool material grade with a post coating treatment
×
Chipping
Chipping
Cause
Caused by either the cutting edge of the insert being too brittle, or a built-up edge has been formed
Remedy
Use inserts, produced from a tougher tool material grade
Use inserts with reinforced cutting edge
Increase cutting speed
Apply cutters with chatter-free geometry
Apply vibration-dampening toolholders
×
Flank Wear
Flank Wear
Cause
High cutting speed
Low wear resistance carbide grade
Remedy
Reduce cutting speed
Use a more wear- resistant cutting tool material grade
Select a more wear resistant grade
For work-hardening materials, select a smaller entry angle
Reduce the cutting speed when machining heat resistant materials
×
Crater Wear
Crater Wear
Cause
Excessive cutting temperatures and pressures on the top of the insert
Remedy
Reduce cutting speed
Reduce feed
Use a tool with more positive geometry
Use a harder material grade
Select a more wear resistant grade
Select a more positive insert geometry
Reduce the cutting speed or reduce the feed rate to lower the temperature
Use higher coolant flow and pressure, consider High pressure coolant
×
Plastic Deformation
Plastic Deformation
Cause
Cutting temperature is too high
Remedy
Reduce cutting speed
Use a harder material grade
Reduce the feed rate
×
Thermal Cracking
Thermal Cracking
Cause
Excessive variations in surface temperature, intermittent machining, or variations in coolant supply
Remedy
Reduce cutting speed
Use tougher cutting tool material grade with higher thermal resistance
Significantly increase coolant supply or turn it off
Select a tougher insert grade
Eliminate the use of coolant whenever possible
×
Edge Fracture
Edge Fracture
Cause
Caused by excessive insert wear before indexing the insert
The grade and geometry could be too weak for the applications
Excessive load on the insert
Built-up edge has been formed on the insert
Remedy
Reduce cutting speed
Use endmills of chatter-free geometry
Use a tougher cutting tool material grade
×
Built-up Edge
Built-up Edge
Cause
Cutting zone temperature is too low
Negative cutting geometry
Machining of very sticky materials such as low-carbon steel, stainless steels, and aluminum
Remedy
Increase cutting speed
Significantly increase coolant supply
Use inserts, produced from a tool material grade with a post coating treatment
×
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