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    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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