Drilling 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- Check that the correct geometry is used
- Increase coolant pressure
- Change to harder grade
- Increase oil concentration percentage
- Reduce cutting speed.*** increase feed
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Crater WearCrater Wear
Cause- Excessive cutting temperatures and pressures on the top of the insert
Remedy- Reduce cutting feed
- Check that the correct geometry is used
-
Plastic DeformationPlastic Deformation
Cause- 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 CrackingThermal Cracking
Cause- Excessive variations in surface temperature, intermittent machining, or variations in coolant supply
Remedy- Increase coolant pressure/volume
- Increase oll concentration percentage
-
Corner FractureCorner 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- Check radial runout
- Reduce feed rate increase the speed
- Check tool and part clamping rigidity
- Check if pocket gripping force is too low, replace the holder
- Increase coolant pressure
- Improve jet direction in case of external coolant supply
-
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 the feed
- Increase cutting speed
- Increase coolant pressure
- Check oil percentage in the coolant fluid
-
Edge ChippingEdge Chipping
Cause- Low wear resistance carbide grade
- Built-up edge has been formed
- Insufficient cutting fluid
Remedy- Reduce feed rate
- Increase cutting speed
- Increase coolant pressure
- Improve jet direction in case of external coolant supply
- Change to different geometry
- Check tool and part clamping rigidity
-
Chisel ChippingChisel Chipping
Cause- Chisel runout is too big
- Combine 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 force is too low, replace the holder
-
Corner ChippingCorner Chipping
Cause- Radial runout is too big
- Insufficient cutting fluid
Remedy- Check radial runout
- Reduce feed rate increase the speed
- Check tool and part clamping rigidity
- Check if pocket gripping force is too low, replace the holder
- Increase coolant pressure
- Improve jet direction in case of external coolant supply
-
Land WearLand Wear
Cause- Cutting speed too high
- Low wear resistance carbide grade
- Radial runout is too big
Remedy- Check that the correct geometry is used
- Check that T.I.R runout 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 force is too low, replace the tool body
-
-
-
Flank WearFlank Wear
Cause- 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 percentage
- Reduce cutting speed.*** increase feed
-
Crater WearCrater Wear
Cause- Excessive cutting temperatures and pressures on the top of the insert.
Remedy
- Reduce cutting feed
- Check that the correct geometry is used
-
Plastic DeformationPlastic Deformation
Cause- 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 CrackingThermal Cracking
Cause- Excessive variations in surface temperature, intermittent machining, or variations in coolant supply
Remedy- Increase coolant pressure/volume
- Increase oll concentration percentage
-
Corner FractureCorner 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- Check radial runout
- Reduce feed rate increase the speed
- Check tool and part clamping rigidity
- Check if pocket gripping force is too low, replace the holder
- Increase coolant pressure
- Improve jet direction in case of external coolant supply
-
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 the feed
- Increase cutting speed
- Increase coolant pressure
- Check oil percentage in the coolant fluid
-
Edge chippingEdge chipping
Cause- 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 ChippingChisel Chipping
Cause- Chisel runout is too big
- Combine 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 force is too low, replace the holder
-
Land WearLand Wear
Cause- Cutting speed too high
- Low wear resistance carbide grade
- Radial runout is too big
Remedy- Check that the correct geometry is used
- Check that T.I.R runout 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 force is too low, replace the tool body
-
Corner ChippingCorner Chipping
Cause- Radial runout is too big
- Insufficient cutting fluid
Remedy- Check radial runout
- Reduce feed rate increase the speed
- Check tool and part clamping rigidity
- Check if pocket gripping force is too low, replace the holder
- Increase coolant pressure
- Improve jet direction in case of external coolant supply
-
-
-
Flank WearFlank 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 percentage
-
Crater WearCrater Wear
Cause- Excessive cutting temperatures and pressures on the top of the insert
Remedyouter insert:
- Reduce cutting speed
- Choose better wear resistance grade
- Change to different chipbreaker
inner insert:
- Reduce feed rate
- Change to different chipbreaker
-
Plastic DeformationPlastic Deformation
Cause- Cutting temperature is too high
Remedy- Reduce feed rate
- Choose better wear resistance grade
- Increase coolant pressure/volume
- Choose a different chipbreaker
-
Thermal CrackingThermal Cracking
Cause- Excessive variations in surface temperature, intermittent machining, or variations in coolant supply
Remedy- Use tougher grade
- Increase coolant pressure/volume
-
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 tougher grade
- Reduce feed rate
- Increase coolant pressure/volume
- Change to different chipbreaker
-
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
- Change to different chipbreaker
- Reduce feed rate
- Increase coolant pressure/volume
-
ChippingChipping
Cause- Low wear resistance carbide grade
- Built-up edge has been formed
- Insufficient cutting fluid
Remedy- Choose tougher grade
- Reduce feed
- Increase coolant pressure/volume
- Change to different chipbreaker
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