Drilling Inserts Wear Problems and Solutions

SOLID CARBIDE

DRILLING - INDEXABLE HEAD

DRILLING - INDEXABLE INSERTS

Type of Wear

- ×
  
  Flank Wear
  Flank 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 Wear
  Crater 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 Deformation
  Plastic 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 Cracking
  Thermal Cracking
  
  Cause
  - Excessive variations in surface temperature, intermittent machining, or variations in coolant supply
  Remedy
  - Increase coolant pressure/volume
  - Increase oll concentration percentage
- ×
  
  Corner Fracture
  Corner 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 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 feed
  - Increase cutting speed
  - Increase coolant pressure
  - Check oil percentage in the coolant fluid
- ×
  
  Edge Chipping
  Edge 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 Chipping
  Chisel 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 Chipping
  Corner 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 Wear
  Land 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 Wear
  Flank 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 Wear
  Crater 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 Deformation
  Plastic 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 Cracking
  Thermal Cracking
  
  Cause
  - Excessive variations in surface temperature, intermittent machining, or variations in coolant supply
  Remedy
  - Increase coolant pressure/volume
  - Increase oll concentration percentage
- ×
  
  Corner Fracture
  Corner 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 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 feed
  - Increase cutting speed
  - Increase coolant pressure
  - Check oil percentage in the coolant fluid
- ×
  
  Edge chipping
  Edge 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 Chipping
  Chisel 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 Wear
  Land 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 Chipping
  Corner 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 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 percentage
- ×
  
  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 a different chipbreaker
- ×
  
  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 tougher grade
  - Reduce feed
  - Increase coolant pressure/volume
  - Change to different chipbreaker