Technical Information
Turning Insert Common Failure Mode & Solutions
Failtures
Picture
Analysis
Solution
● Tool material is too soft ● Excessive cutting speed ● Too small clearance angle
● Choose high wear-resistant insert grade ● Reduce cutting speed ● Enlarge clearance angle ● Increase feed rate ● Choose high wear-resistant insert grade ● Reduce cutting speed ● Reduce feed rate ● Increase the flow of coolant
Flank wear
● Too low feed rate ● Insufficient cooling
● Tool material is too soft ● Excessive cutting speed ● Excessive feed rate
Crater wear
● Choose tougher grade ● Enhance cutting edge strength
● Tool material is too hard ● Too low cutting edge strength
Chipping
● Choose high wear-resistant insert grade ● Reduce cutting speed ● Reduce cutting depth & feed rate ● Choose good thermal conductivity grade ● Increase the flow of coolant ● Increase cutting speed ● Choose sharp geometry ● Choose less adhesion grade ● Increase the flow of coolant ● Choose tougher grade ● Choose a smaller approach angle ● Choose bigger corner radius ● Change to high rigidity holder
● Tool material is too soft ● Too fast cutting speed ● Excessive cutting depth & feed rate ● Insufficient cooling
Plastic deformation
● Too low cutting speed ● Cutting edge not sharp ● Unsuitable grade ● Insufficient cooling
Built-up edge
● Excessive feed rate and cutting depth ● Vibration
Mechanical wear
● Choose dry cutting or adequate cooling ● Choose tougher grade
● Excessive cutting heat change on edge
Thermal cracking
● Excessive feed rate & cutting speed ● Tool material is too soft
● Choose high wear-resistane grade ● Select a small entering angle ● Reduce cutting speed
Notch wear
● Sticky chip on the cutting edge ● Chip evacuation failure
● Enlarge rake angle for a sharp edge ● Use chip breaker with bigger chip space
Coating peeling
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