ISO Turn Inserts Wear Problems and Solutions

ISO Turning


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

      Remedy
      • Use harder cutting tool material
      • Reduce cutting speed
      • Increase coolant preesure and check coolant direction
      • 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
      • Use geometry with greater rake angle
      • Use more wear - resistant cutting tool material
      • Reduce feed rate
      • Increase coolant preesure and check coolant direction
    • ×
      Plastic Deformation
      Plastic Deformation
      Cause
      • Cutting temperature is too high

      Remedy
      • Select more wear resistant cutting material
      • Reduce the feed rate
      • Reduce the cutting speed
      • Reduce the cutting depth
      • Increase coolant pressure
    • ×
      Notch Wear
      Notch Wear
      Cause
      • High hardness of the material surface causes damage at the depth of cut line

      Remedy
      • Vary the cutting depth
      • Use tool with a leading cutting edge
      • Select a smaller corner radius
      • Increase coolant pressure
      • Select a more wear resistant grade
      • 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
      • Reduce feed rate
      • Use tougher cutting tool material
      • Turn off coolant supply when machining interrupted cuts
      • Use more stable geometry
      • 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
      • Use a tougher cutting tool material
      • Reduce the cutting speed
      • Use a stronger cutting edge
      • Check the tool stability if vibration occurs
      • Reduce the feed rate
      • Turn off coolant supply when machining interrupted cuts
      • Increase corner radius if possible
      • 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 a sharper cutting edge
      • Use cutting tool material with a treated (smoother) surface
      • Increase coolant supply
    • ×
      Chip Hammering
      Chip Hammering
      Cause
      • Chips curling into insert

      Remedy
      • Try a different chip breaker with stronger geometry
      • Alter feed rate and/or cutting speed
    • ×
      Chipping
      Chipping
      Cause
      • Caused by either the cutting edge of the insert being too brittle, or a built-up edge has been formed

      Remedy
      • Select a tougher grade
      • Reduce the feedrate
      • Select a chipformer with a stronger cutting edge
      • Check tool clamping stability
      • Increase cutting speed
      • Reduce feed rate at beginning of cut
      • Improve stability of the set-up
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