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    钻削刀片磨损原因及解决方案

    整体硬质合金钻头
    可换头式钻头
    可换刀片式钻头


    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
        • 检查所用刀具形状是否正确
        • 提高冷却液压力
        • 更换为硬度更高的牌号
        • 提高冷却液里油浓度百分比
        • 降低切削速度。***提高进给
      • ×
        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
        • 降低进给
        • 检查所用刀具形状是否正确
      • ×
        塑性变形
        塑性变形
        原因
        • 切削温度过高

        解决方案
        • 检查切削参数
        • 降低进给
        • 提高冷却液压力 / 冷却液流量
        • 采用硬度更高的牌号
        • 检查所用刀具形状是否正确
      • ×
        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
        • 提高冷却液压力 / 冷却液流量
        • 提高冷却液中油含量百分比
      • ×
        切削刃外侧破损
        切削刃外侧破损
        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

        解决方案
        • 检查钻头径向跳动
        • 降低进给率,提高切削速度
        • 检查刀具及工件的夹持刚性
        • 检查定位槽夹持力是否过低,更换钻杆
        • 提高冷却液压力
        • 采用外冷加工时,调整冷却射流方向使其更精准
      • ×
        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
        • 提高进给
        • 提高切削速度
        • 提高冷却液压力
        • 检查冷却液中油含量百分比
      • ×
        切削刃崩刃
        切削刃崩刃
        原因
        • 硬质合金牌号不耐磨
        • 刀片已形成了积屑瘤
        • 切削液供应不足

        解决方案
        • 降低进给率
        • 提高切削速度
        • 提高冷却液压力
        • 采用外冷加工时,调整冷却射流方向使其更精准
        • 更换为不同形状的钻头
        • 检查刀具及工件的夹持刚性
      • ×
        横刃崩刃
        横刃崩刃
        原因
        • 横刃跳动太大
        • 结合了高进给 & 低切削速度

        解决方案
        • 降低进给率并提高切削速度
        • 检查横刃错位不超过0.02mm
        • 检查刀具及工件的夹持刚性
        • 检查定位槽夹持力是否过低,更换钻杆
      • ×
        切削刃外侧崩刃
        切削刃外侧崩刃
        原因
        • 径向跳动太大
        • 切削液供应不足

        解决方案
        • 检查钻头径向跳动
        • 降低进给率,提高切削速度
        • 检查刀具及工件的夹持刚性
        • 检查定位槽夹持力是否过低,更换钻杆
        • 提高冷却液压力
        • 采用外冷加工时,调整冷却射流方向使其更精准
      • ×
        棱边磨损
        棱边磨损
        原因
        • 切削速度过高
        • 硬质合金牌号不耐磨
        • 径向跳动太大

        解决方案
        • 检查所用刀具形状是否正确
        • 检查 刀尖跳动T.I.R不超过0.02mm
        • 降低切削速度
        • 提高冷却液压力
        • 采用外冷加工时,调整冷却射流方向使其更精准
        • 检查并提高刀具及工件的夹持刚性
        • 检查定位槽夹持力是否过低,更换钻杆
      • ×
        Flank Wear
        Flank Wear
        原因
        • High cutting speed
        • Low wear resistance carbide grade

        Remedy
        • Check that the correct geometry is used
        • Increase coolant pressure
        • Change to harder grade
        • Increase oil concentration presentage
        • Reduce cutting speed.*** increase feed
      • ×
        Crater Wear
        Crater Wear
        原因
        • Excessive cutting temperatures and pressures on the top of the insert.

        Remedy

        • Reduce cutting feed
        • Check that the correct geometry is used
      • ×
        Plastic Deformation
        Plastic Deformation
        原因
        • Cutting temperature is too high

        Remedy
        • Check cutting parameters
        • Reduce cutting feed
        • Increase coolant pressure/volume
        • Use harder grade
        • Check that the correct geometry is used
      • ×
        Thermal Cracking
        Thermal Cracking
        原因
        • Excessive variations in surface temperature, intermittent machining, or variations in coolant supply

        Remedy
        • Increase coolant pressure/volume
        • Increase oll concentration presentage
      • ×
        Corner Fracture
        Corner Fracture
        原因
        • 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
        • Check radial run-out
        • Reduce feed rate increase the speed
        • Check tool and part clamping rigidity
        • Check if pocket gripping forces is too low, replace the holder
        • Increase coolant pressure
        • Improve jet direction in case of external coolant supply
      • ×
        Built-up Edge
        Built-up Edge
        原因
        • 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 feed
        • Increase cutting speed
        • Increase coolant pressure
        • Check oil percentage in the coolant fluid
      • ×
        Edge chipping
        Edge chipping
        原因
        • Low wear resistance carbide grade
        • Built-up edge has been formed
        • Insufficient cutting fluid

        Remedy
        • Reduce feed rate
        • Increase the speed
        • Increase coolant pressure
        • Improve jet direction in case of external coolant supply
        • Change to different geometry
        • Check tool and part clamping rigidity
      • ×
        Chisel Chipping
        Chisel Chipping
        原因
        • Chisel run-out is too big
        • Combine of high feed & low speed

        Remedy
        • Reduce feed rate and increase the cutting speed
        • Check that chisel misalignment does not exceed 0.02mm
        • Check tool and part clamping rigidity
        • Check if pocket gripping forces is too low, replace the holder
      • ×
        Land Wear
        Land Wear
        原因
        • Cutting speed too high
        • Low wear resistance carbide grade
        • Radial run-out is too big

        Remedy
        • Check that the correct geometry is used
        • Check that T.I.R run-out does not exceed 0.02mm
        • Reduce cutting speed
        • Increase coolant pressure
        • Improve jet direction in case of external coolant supply
        • Check and improve tool and part clamping rigidity
        • Check if pocket gripping forces is too low, replace the tool body
      • ×
        Corner Chipping
        Corner Chipping
        原因
        • Radial run-out is too big
        • Insufficient cutting fluid

        Remedy
        • Check radial run-out
        • Reduce feed rate increase the speed
        • Check tool and part clamping rigidity
        • Check if pocket gripping forces is too low, replace the holder
        • Increase coolant pressure
        • Improve jet direction in case of external coolant supply
      • ×
        Flank Wear
        Flank Wear
        Cause
        • High cutting speed
        • Low wear resistance carbide grade

        Remedy
        • Reduce cutting speed
        • Increase coolant pressure/volume
        • Choose better wear resistance grade
        • Increase oil concentration presentage
      • ×
        Crater Wear
        Crater Wear
        Cause
        • Excessive cutting temperatures and pressures on the top of the insert

        Remedy
        outer insert:
        • Reduce cutting speed
        • Choose better wear resistance grade
        • Change to different chipbreaker

        inner insert:
        • Reduce feed rate
        • Change to different chipbreaker
      • ×
        Plastic Deformation
        Plastic Deformation
        Cause
        • Cutting temperature is too high

        Remedy
        • Reduce feed rate
        • Choose better wear resistance grade
        • Increase coolant pressure/volume
        • Choose diferent chip-breaker
      • ×
        Thermal Cracking
        Thermal Cracking
        Cause
        • Excessive variations in surface temperature, intermittent machining, or variations in coolant supply

        Remedy
        • Use tougher grade
        • Increase coolant pressure/volume
      • ×
        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 tougher grade
        • Reduce feed rate
        • Increase coolant pressure/volume
        • Change to different chipbreaker
      • ×
        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
        • Change to different chipbreaker
        • Reduce feed rate
        • Increase coolant pressure/volume
      • ×
        Chipping
        Chipping
        Cause
        • Low wear resistance carbide grade
        • Built-up edge has been formed
        • Insufficient cutting fluid

        Remedy
        • Choose tougheer grade
        • Reduce feed
        • Increase coolant pressure/volume
        • Change to different chipbreaker
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