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Milling Inserts Wear Problems and Solutions

MILLING INDEXABLE INSERTS
MILLING - SOLID&MM


Type of Wear
    • ×
      Flank Wear
      Flank Wear
      Cause
      • High cutting speed
      • Low wear resistance carbide grade

      Remedy
      • Reduce cutting speed
      • Use a more wear- resistant cutting tool material 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
      • Reduce cutting speed
      • Reduce feed
      • Use a tool with more positive geometry
      • Use a harder material grade
      • 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
      • Reduce cutting speed
      • Use a harder material grade
      • Significantly increase coolant supply
    • ×
      Notch Wear
      Notch Wear
      Cause
      • Cutting speed is too high, or insufficient insert wear resistance of the carbide grade

      Remedy
      • Use more wear resistant tool material grade
      • Reduce cutting speed
      • Vary cutting depth
      • Use insert with a reinforced cutting edge geometry
      • For work-hardening materials, select a smaller entry angle
      • Reduce the cutting speed when machining heat resistant materials
    • ×
      Thermal Cracking
      Thermal Cracking
      Cause
      • Excessive variations in surface temperature, intermittent machining, or variations in coolant supply

      Remedy
      • Reduce cutting speed
      • Use tougher cutting tool material grade
      • Significantly increase coolant supply or turn it off
      • 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 inserts with larger corner radius / chamfer, preferrably single-sided
      • Use cutters of chatter-free geometry
      • Use a tougher cutting tool material grade
      • Reduce feed
      • Apply vibration-dampening toolholders
    • ×
      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 cutters with more positive rake angle and sharper cutting edge
      • Significantly increase coolant supply
      • Use inserts, produced from a tool material grade with a post coating treatment
    • ×
      Chipping
      Chipping
      Cause
      • Caused by either the cutting edge of the insert being too brittle, or a built-up edge has been formed

      Remedy
      • Use inserts, produced from a tougher tool material grade
      • Use inserts with reinforced cutting edge
      • Increase cutting speed
      • Apply cutters with chatter-free geometry
      • Apply vibration-dampening toolholders
    • ×
      Flank Wear
      Flank Wear
      Cause
      • High cutting speed
      • Low wear resistance carbide grade

      Remedy
      • Reduce cutting speed
      • Use a more wear- resistant cutting tool material 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
      • Reduce cutting speed
      • Reduce feed
      • Use a tool with more positive geometry
      • Use a harder material grade
      • 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
      • Reduce cutting speed
      • Use a harder material grade
      • Reduce the feed rate
    • ×
      Thermal Cracking
      Thermal Cracking
      Cause
      • Excessive variations in surface temperature, intermittent machining, or variations in coolant supply

      Remedy
      • Reduce cutting speed
      • Use tougher cutting tool material grade with higher thermal resistance
      • Significantly increase coolant supply or turn it off
      • Select a tougher insert grade
      • 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
      • Reduce cutting speed
      • Use endmills of chatter-free geometry
      • Use a tougher cutting tool material 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
      • Significantly increase coolant supply
      • Use inserts, produced from a tool material grade with a post coating treatment
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