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车削-切槽 & 切断加工
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刀片磨损原因及解决方案
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车削-切槽刀片 & 切断刀片磨损原因及解决方案
车削-切槽刀片 & 切断刀片磨损原因及解决方案
车削-切槽刀片
切断
端面切槽
磨损类型
×
后刀面磨损
后刀面磨损
原因
切削速度高
硬质合金牌号不耐磨
解决方案
降低切削速度
采用耐磨性更佳的牌号
提高冷却液压力
调整刀片中心高度
×
月牙洼磨损
月牙洼磨损
原因
刀片切削区域切削温度过高,压力过大
解决方案
降低切削速度
降低进给率
采用耐磨性更佳的牌号
提高冷却液压力
采用带大正前角的刀片
×
塑性变形
塑性变形
原因
切削温度过高
解决方案
降低切削速度
降低进给率
采用耐磨性更佳的牌号
提高冷却液压力
×
沟槽磨损
沟槽磨损
原因
切削速度过高,或刀片牌号不耐磨
解决方案
降低切削速度
降低进给率
采用耐磨性更佳的牌号
调整切削深度
提高冷却液压力
×
热裂
热裂
原因
切削区域表面温度变化太大,断续切削,或冷却液供应产生变化
解决方案
降低切削速度
降低进给率
采用韧性更佳的牌号
采用更强固的切削刃
断续切削时停止供应冷却液
×
切削刃破损
切削刃破损
原因
更换刀片切削刃前,刀片过度磨损
对于该应用而言,刀片牌号及几何形状都太弱了
刀片载荷过大
刀片已形成了积屑瘤
原因
降低切削速度
采用韧性更佳的牌号
降低进给率
采用更强壮的刀体
采用更强固的负前角刀片
采用螺钉夹持式替代自夹式
调整刀片中心高度
减小刀具悬伸
×
积屑瘤
积屑瘤
原因
切削区域温度太低
负型刀片
加工材料粘性高,如低碳钢,不锈钢及铝
解决方案
提高切削速度
采用带锋利切削刃的可转位刀片
提高冷却液压力
×
Flank Wear
Flank Wear
Cause
High cutting speed
Low wear resistance carbide grade
Remedy
Reduce cutting speed
Use harder grade
Increase coolant pressure
Adjust center height position
×
Crater Wear
Crater Wear
Cause
Excessive cutting temperatures and pressures on the top of the insert.
Remedy
Use harder grade
Reduce cutting speed
Increase coolant pressure
Use an insert with a positive cutting rake
×
Plastic Deformation
Plastic Deformation
Cause
Cutting temperature is too high
Remedy
Use harder grade
Reduce feed rate
Reduce cutting speed
Increase coolant pressure
×
Notch Wear
Notch Wear
Cause
Cutting speed too high, or insufficient insert wear resistance of the carbide grade
Remedy
Reduce the cutting speed
Use harder grade
Use reinforced cutting edge negative cutting rake
Adjust center height position
Increase the coolant pressure
×
Thermal Cracking
Thermal Cracking
Cause
Excessive variations in surface temperature, intermittent machining, or variations in coolant supply
Remedy
Reduce cutting speed
Reduce feed rate
Use tougher grade
Use stronger edge geometry
Turn off coolant supply when machining interrupted cuts
×
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 the cutting speed
Use tougher grade
Reduce feed rate
Reduce tool extension
Use more stable tool holder
Use reinforced cutting edge negative cutting rake
Use screw clamping instead of self clamping
Check center height position
Use screw clamping instead of self- clamping
×
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 the cutting speed
Use an insert with a positive cutting rake
Increase the coolant pressure
×
Flank Wear
Flank Wear
Cause
High cutting speed
Low wear resistance carbide grade
Remedy
Reduce cutting speed
Use harder grade
Increase coolant pressure
Adjust center height position
×
Crater Wear
Crater Wear
Cause
Excessive cutting temperatures and pressures on the top of the insert.
Remedy
Use harder grade
Reduce cutting speed
Increase coolant pressure
Use an insert with a positive cutting rake
×
Plastic Deformation
Plastic Deformation
Cause
Cutting temperature is too high
Remedy
Use harder grade
Reduce feed rate
Reduce cutting speed
Increase coolant pressure
×
Notch Wear
Notch Wear
Cause
Cutting speed too high, or insufficient insert wear resistance of the carbide grade
Remedy
Reduce the cutting speed
Use harder grade
Use reinforced cutting edge negative cutting rake
Adjust center height position
Increase the coolant pressure
×
Thermal Cracking
Thermal Cracking
Cause
Excessive variations in surface temperature, intermittent machining, or variations in coolant supply
Remedy
Reduce cutting speed
Reduce feed rate
Use tougher grade
Use stronger edge geometry
Turn off coolant supply when machining interrupted cuts
×
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 tougher grade
Reduce feed rate
Reduce tool extension
Use more stable tool holder
Use reinforced cutting edge negative cutting rake
Check center height
Use screw clamping instead of self- clamping
×
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 the cutting speed
Use an insert with a positive cutting rake
Increase the coolant pressure
×
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