Technical Information
Solid Carbide Endmill Failure Mode and Solutions
Failure
Picture
Analysis
Solution
● Reduce cutting speed ● Use a more wear-resistant cutting tool material ● Increase feed ● Raise coolant flow (e.g. raise coolant pressure)
Flank wear
● Abrasion between the work piece and the flank surface leads to flank wear.
● Raise cutting speed ● Use more positive geometry, use a tool with a sharper cutting edge/use a sharper indexable insert ● Reduce the feed rate ● Increase the amount of grease in the coolant (e.g. 8% oil content in coolant) ● Use uncoated grade with polished geometry (e.g. for non-ferrous metals)
Built-up edge
● The work piece material stick on the cutting edge leads to built-up edge.
Fractures
● Use a tougher cutting tool material ● Reduce cutting speed ● Change to dry machining ● Adjust feed rate
● Perpendicular cracks along the edge lead to fractures. ● Vibration causes fractures.
● Reduce cutting speed ● Reduce feed rate ● Use a more wear-resistant cutting tool material ● Use a less sharp tool ● Optimize the coolant towards to the cutting edge
Plastic deformation
● High heat and mechanical stress cause plastic deformation.
● Reduce cutting speed ● Reduce feed rate ● Dry machining or use adequate coolant ● Use a PVD-coated (tougher) indexable insert grade
Thermal cracks
● Fluctuating temperature (thermal shock) causes thermal cracks.
Notch wear
● Notch wear often occurs during machining work pieces with a hard surface (forged, casted or cold work hardened).
● Change depth of cut ● Use a tougher cutting tool material ● Use a smaller approach angle ● Use a stronger geometry (with chamfer)
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