Flank Wear

• High cutting speed
• Low wear resistance carbide grade

• Check that the correct geometry is used
• Increase coolant pressure
• Change to harder grade
• Increase oil concentration percentage
• Reduce cutting speed.*** increase feed

Crater Wear

• Excessive cutting temperatures and pressures on the top of the insert

• Reduce cutting feed
• Check that the correct geometry is used

Plastic Deformation

• Cutting temperature is too high

• Check cutting parameters
• Reduce cutting feed
• Increase coolant pressure/volume
• Use harder grade
• Check that the correct geometry is used

Thermal Cracking

• Excessive variations in surface temperature, intermittent machining, or variations in coolant supply

• Increase coolant pressure/volume
• Increase oll concentration percentage

Corner Fracture

• 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

• 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 Edge

• Cutting zone temperature is too low
• Negative cutting geometry
• Machining of very sticky materials such as low-carbon steel, stainless steels, and aluminum

• Increase the feed
• Increase cutting speed
• Increase coolant pressure
• Check oil percentage in the coolant fluid

Edge Chipping

• Low wear resistance carbide grade
• Built-up edge has been formed
• Insufficient cutting fluid

• 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 Chipping

• Chisel runout is too big
• Combine high feed & low speed

• 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 Chipping

• Radial runout is too big
• Insufficient cutting fluid

• 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 Wear

• Cutting speed too high
• Low wear resistance carbide grade
• Radial runout is too big

• 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 Wear

• High cutting speed
• Low wear resistance carbide grade

• Check that the correct geometry is used
• Increase coolant pressure
• Change to harder grade
• Increase oil concentration percentage
• Reduce cutting speed.*** increase feed

Crater Wear

• Excessive cutting temperatures and pressures on the top of the insert.

• Reduce cutting feed
• Check that the correct geometry is used

Plastic Deformation

• Cutting temperature is too high

• Check cutting parameters
• Reduce cutting feed
• Increase coolant pressure/volume
• Use harder grade
• Check that the correct geometry is used

Thermal Cracking

• Excessive variations in surface temperature, intermittent machining, or variations in coolant supply

• Increase coolant pressure/volume
• Increase oll concentration percentage

Corner Fracture

• 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

• 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 Edge

• Cutting zone temperature is too low
• Negative cutting geometry
• Machining of very sticky materials such as low-carbon steel, stainless steels, and aluminum

• Increase the feed
• Increase cutting speed
• Increase coolant pressure
• Check oil percentage in the coolant fluid

Edge chipping

• Low wear resistance carbide grade
• Built-up edge has been formed
• Insufficient cutting fluid

• 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 runout is too big
• Combine high feed & low speed

• 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 Wear

• Cutting speed too high
• Low wear resistance carbide grade
• Radial runout is too big

• 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 Chipping

• Radial runout is too big
• Insufficient cutting fluid

• 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 Wear

• High cutting speed
• Low wear resistance carbide grade

• Reduce cutting speed
• Increase coolant pressure/volume
• Choose better wear resistance grade
• Increase oil concentration percentage

Crater Wear

• Excessive cutting temperatures and pressures on the top of the insert

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

• Cutting temperature is too high

• Reduce feed rate
• Choose better wear resistance grade
• Increase coolant pressure/volume
• Choose a different chipbreaker

Thermal Cracking

• Excessive variations in surface temperature, intermittent machining, or variations in coolant supply

• Use tougher grade
• Increase coolant pressure/volume

Edge Fracture

• 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

• Use tougher grade
• Reduce feed rate
• Increase coolant pressure/volume
• Change to different chipbreaker

Built-up Edge

• Cutting zone temperature is too low
• Negative cutting geometry
• Machining of very sticky materials such as low-carbon steel, stainless steels, and aluminum

• Increase cutting speed
• Change to different chipbreaker
• Reduce feed rate
• Increase coolant pressure/volume

Chipping

• Low wear resistance carbide grade
• Built-up edge has been formed
• Insufficient cutting fluid

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