Technical Guidance Cutting Edge Failure and Countermeasures, Turning Edition
■ Insert Failure and Countermeasures Insert Failure
Cause
Countermeasures
Flank Wear
· Tool grade lacks wear resistance
· Select a more wear-resistant grade P30 → P20 → P10 K20 → K10 → K01 · Increase rake angle · Decrease cutting speed · Increase feed rate
· Cutting speed is too fast · Feed rate is far too slow
N
Crater Wear
· Tool grade lacks crater wear resistance · Rake angle is too small
· Select a more crater wear-resistant grade · Increase rake angle · Change the chipbreaker of the insert · Decrease cutting speed · Reduce feed rate and depth of cut
· Cutting speed is too fast · Feed rate and depth of cut are too large
Cutting Edge Chipping
· Tool grade lacks toughness
· Select a tougher grade P10 → P20 → P30 K01 → K10 → K20 · Increase amount of honing on cutting edge · Reduce rake angle · Reduce feed rate and depth of cut · Select a tougher grade P10 → P20 → P30 K01 → K10 → K20 · Select an insert chipbreaker with a strong cutting edge · Select a holder with a larger approach angle · Select a holder with a larger shank size · Reduce feed rate and depth of cut · Select a grade with less affinity to the work material Coated carbide or cermet grades · Select a grade with a smooth coating · Increase rake angle · Reduce honing · Increase cutting speed · Increase feed rate
· Cutting edge breaks off due to chip adhesion · Cutting edge is not strong enough · Feed rate and depth of cut are too large
Cutting Edge Fracture
· Tool grade lacks toughness
· Cutting edge is not strong enough
· Holder is not strong enough
· Feed rate and depth of cut are too large
Adhesion/Built-up Edges
· Inappropriate grade selection
· Cutting edge is not sharp enough
· Cutting speed is too slow · Feed rate is too slow
Plastic Deformation
· Select a more crater wear-resistant grade · Increase rake angle · Decrease cutting speed · Reduce feed rate and depth of cut · Supply sufficient coolant
· Tool grade lacks thermal resistance
· Cutting speed is too fast · Feed rate and depth of cut are too large · Not enough coolant
Notch Wear
· Tool grade lacks wear resistance
· Select a more wear-resistant grade P30 → P20 → P10 K20 → K10 → K01 · Increase rake angle · A lter depth of cut to shift the notch location
· Rake angle is too small · Cutting speed is too fast
N38
Made with FlippingBook flipbook maker