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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
      • Reduce cutting speed
      • Increase coolant pressure
      • change to harder grade
      • Select a more wear resistant grade
      • For work-hardening materials, select a smaller entry angle
      • Reduce the cutting speed when machining heat resistant materials
    • ×
      Crater Wear
      Crater Wear
      Cause
      • Excessive cutting temperatures and pressures on the top of the insert

      Remedy
      • Select a more wear resistant grade
      • Select a more positive insert geometry
      • Reduce the cutting speed or reduce the feed rate to lower the temperature
      • Use higher coolant flow and pressure, consider High pressure coolant
    • ×
      Plastic Deformation
      Plastic Deformation
      Cause
      • Cutting temperature is too high

      Remedy
      • Check cutting parameters
      • Reduce cutting speed/feed
      • Increase coolant pressure/volume
      • Use harder grade
      • Select a harder, more wear resistant grade
      • Reduce the cutting speed
      • Reduce the feed rate
    • ×
      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
      • 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
      • Reduce feed and/or depth of cut
      • Select a stronger or thicker insert and tougher grade
    • ×
      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
      • Cutting zone temperature is too low
      • Negative cutting geometry
      • Machining of very sticky materials such as low-carbon steel, stainless steels, and aluminum
    • ×
      Flank Wear
      Flank Wear
      Cause
      • High cutting speed
      • Low wear resistance carbide grade

      Remedy
      • Check that the correct geometry is used
      • Reduce cutting speed
      • Increase coolant pressure
      • change to harder grade
      • Select a more wear resistant grade
      • For work-hardening materials, select a smaller entry angle
      • Reduce the cutting speed when machining heat resistant materials
    • ×
      Plastic Deformation
      Plastic Deformation
      Cause
      • Cutting temperature is too high

      Remedy
      • Check cutting parameters
      • Reduce cutting speed/feed
      • Increase coolant pressure/volume
      • Use harder grade
      • Select a harder, more wear resistant grade
    • ×
      Thermal Cracking
      Thermal Cracking
      Cause
      • Excessive variations in surface temperature, intermittent machining, or variations in coolant supply

      Remedy
      • increase coolant pressure/volume
      • Select a tougher insert grade
      • Eliminate the use of coolant whenever possible
    • ×
      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
      • Cutting zone temperature is too low
      • Negative cutting geometry
      • Machining of very sticky materials such as low-carbon steel, stainless steels, and aluminum
    • ×
      Chipping
      Edge Chipping
      Cause
      •  

      Remedy
      • Reduce feed rate
      • Increase the speed
      • Increase coolant pressure
      • Improve jet direction in case of external coolant supply
      • Check tool and part clamping rigidity
    • ×
      Chisel Chipping
      Chisel Chipping
      Cause
      •  

      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
      Cause
      •  

      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
      Cause
      •  

      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
      • Select a more wear resistant grade
      • For work-hardening materials, select a smaller entry angle
      • Reduce the cutting speed when machining heat resistant materials
    • ×
      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
      • Use more positive geometry

      inner insert:
      • Reduce feed rate
      • Use more positive geometry


      • Reduce the cutting speed or reduce the feed rate to lower the temperature
      • Use higher coolant flow and pressure, consider high pressure coolant
    • ×
      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
      • Select a harder, more wear resistant grade
      • Reduce the cutting speed
      • Reduce the feed rate
    • ×
      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
      • Eliminate the use of coolant whenever possible
    • ×
      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
      • Reduce feed and/or depth of cut
      • Select a stronger or thicker insert and tougher grade
    • ×
      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
      • Use more positive geometry
      • Reduce feed rate
      • Increase coolant pressure/volume
      • Cutting zone temperature is too low
      • Negative cutting geometry
      • Machining of very sticky materials such as low-carbon steel, stainless steels, and aluminum
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