ISO Turn Inserts Wear Problems and Solutions
Type of Wear
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Flank WearFlank Wear
Cause- High cutting speed
- Low wear resistance carbide grade
Remedy- Use harder cutting tool material
- Reduce cutting speed
- Increase coolant preesure and check coolant direction
- For work-hardening materials, select a smaller entry angle
- Reduce the cutting speed when machining heat resistant materials
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Crater WearCrater Wear
Cause- Excessive cutting temperatures and pressures on the top of the insert
Remedy- Reduce cutting speed
- Use geometry with greater rake angle
- Use more wear - resistant cutting tool material
- Reduce feed rate
- Increase coolant preesure and check coolant direction
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Plastic DeformationPlastic Deformation
Cause- Cutting temperature is too high
Remedy- Select more wear resistant cutting material
- Reduce the feed rate
- Reduce the cutting speed
- Reduce the cutting depth
- Increase coolant pressure
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Notch WearNotch Wear
Cause- High hardness of the material surface causes damage at the depth of cut line
Remedy- Vary the cutting depth
- Use tool with a leading cutting edge
- Select a smaller corner radius
- Increase coolant pressure
- Select a more wear resistant grade
- For work-hardening materials, select a smaller entry angle
- Reduce the cutting speed when machining heat resistant materials
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Thermal CrackingThermal Cracking
Cause- Excessive variations in surface temperature, intermittent machining, or variations in coolant supply
Remedy- Reduce cutting speed
- Reduce feed rate
- Use tougher cutting tool material
- Turn off coolant supply when machining interrupted cuts
- Use more stable geometry
- Select a tougher insert grade
- Eliminate the use of coolant whenever possible
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Edge FractureEdge 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 a tougher cutting tool material
- Reduce the cutting speed
- Use a stronger cutting edge
- Check the tool stability if vibration occurs
- Reduce the feed rate
- Turn off coolant supply when machining interrupted cuts
- Increase corner radius if possible
- Reduce feed and/or depth of cut
- Select a stronger or thicker insert and tougher grade
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Built-up EdgeBuilt-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 a sharper cutting edge
- Use cutting tool material with a treated (smoother) surface
- Increase coolant supply
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Chip HammeringChip Hammering
Cause- Chips curling into insert
Remedy- Try a different chip breaker with stronger geometry
- Alter feed rate and/or cutting speed
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ChippingChipping
Cause- Caused by either the cutting edge of the insert being too brittle, or a built-up edge has been formed
Remedy- Select a tougher grade
- Reduce the feedrate
- Select a chipformer with a stronger cutting edge
- Check tool clamping stability
- Increase cutting speed
- Reduce feed rate at beginning of cut
- Improve stability of the set-up
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