X
 |
Our website uses cookies and other technologies to ensure you get the best browsing experience. You can change your cookie settings at any time. Find out more on how we use cookies. |
INDUSTREALIZE
Contact Us
Milling Inserts Wear Problems and Solutions
MILLING - INDEXABLE INSERTS
MILLING -
SOLID CARBIDE AND
MULTI-MASTER
SOLID CARBIDE AND
MULTI-MASTER
Type of Wear
-
-
Flank WearFlank Wear
Cause- High cutting speed
- Low wear resistance carbide grade
Remedy- Reduce cutting speed
- Use a more wear- resistant cutting tool material grade
- Select a more wear resistant grade
- For work-hardening materials, select a smaller entry angle
- Reduce the cutting speed when machining heat resistant materials
-
Crater WearCrater Wear
Cause- Excessive cutting temperatures and pressures on the top of the insert
Remedy- Reduce cutting speed
- Reduce feed
- Use a tool with more positive geometry
- Use a harder material grade
- Select a more wear resistant grade
- Select a more positive insert geometry
- Reduce the cutting speed or reduce the feed rate to lower the temperature
- Use higher coolant flow and pressure, consider High pressure coolant
-
Plastic DeformationPlastic Deformation
Cause- Cutting temperature is too high
Remedy- Reduce cutting speed
- Use a harder material grade
- Significantly increase coolant supply
-
Notch WearNotch Wear
Cause- Cutting speed is too high, or insufficient insert wear resistance of the carbide grade
Remedy- Use more wear resistant tool material grade
- Reduce cutting speed
- Vary cutting depth
- Use insert with a reinforced cutting edge geometry
- For work-hardening materials, select a smaller entry angle
- Reduce the cutting speed when machining heat resistant materials
-
Thermal CrackingThermal Cracking
Cause- Excessive variations in surface temperature, intermittent machining, or variations in coolant supply
Remedy- Reduce cutting speed
- Use tougher cutting tool material grade
- Significantly increase coolant supply or turn it off
- Eliminate the use of coolant whenever possible
-
Edge FractureEdge 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 inserts with larger corner radius / chamfer, preferrably single-sided
- Use cutters of chatter-free geometry
- Use a tougher cutting tool material grade
- Reduce feed
- Apply vibration-dampening toolholders
-
Built-up EdgeBuilt-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 cutters with more positive rake angle and sharper cutting edge
- Significantly increase coolant supply
- Use inserts, produced from a tool material grade with a post coating treatment
-
ChippingChipping
Cause- Caused by either the cutting edge of the insert being too brittle, or a built-up edge has been formed
Remedy- Use inserts, produced from a tougher tool material grade
- Use inserts with reinforced cutting edge
- Increase cutting speed
- Apply cutters with chatter-free geometry
- Apply vibration-dampening toolholders
-
-
-
Flank WearFlank Wear
Cause- High cutting speed
- Low wear resistance carbide grade
Remedy- Reduce cutting speed
- Use a more wear- resistant cutting tool material grade
- Select a more wear resistant grade
- For work-hardening materials, select a smaller entry angle
- Reduce the cutting speed when machining heat resistant materials
-
Crater WearCrater Wear
Cause- Excessive cutting temperatures and pressures on the top of the insert
Remedy- Reduce cutting speed
- Reduce feed
- Use a tool with more positive geometry
- Use a harder material grade
- Select a more wear resistant grade
- Select a more positive insert geometry
- Reduce the cutting speed or reduce the feed rate to lower the temperature
- Use higher coolant flow and pressure, consider High pressure coolant
-
Plastic DeformationPlastic Deformation
Cause- Cutting temperature is too high
Remedy- Reduce cutting speed
- Use a harder material grade
- Reduce the feed rate
-
Thermal CrackingThermal Cracking
Cause- Excessive variations in surface temperature, intermittent machining, or variations in coolant supply
Remedy- Reduce cutting speed
- Use tougher cutting tool material grade with higher thermal resistance
- Significantly increase coolant supply or turn it off
- Select a tougher insert grade
- Eliminate the use of coolant whenever possible
-
Edge FractureEdge 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- Reduce cutting speed
- Use endmills of chatter-free geometry
- Use a tougher cutting tool material grade
-
Built-up EdgeBuilt-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
- Significantly increase coolant supply
- Use inserts, produced from a tool material grade with a post coating treatment
-
About Us
Overview Founders Ethics Code Research & Development Production Quality Assurance Global Company REACH Global Policy Conflict Minerals ISCAR SeminarsProduct Lines
Parting & Grooving Turning Miniature Hole Making Milling Toolholding Threading Microtools Division Grades Insert WearCompany
Contact Us Terms of Use and Legal Disclaimer Privacy Statement YouTube Terms of Service Meta Quest Privacy Data PoliciesNews & Publications
New Product Announcements Catalogs Brochures Reference and User Guides Latest Articles ISCAR World Magazine Podcast Video ChannelISCAR Sustainability
ISCAR Sustainability Main Production and Environment R&D at ISCAR Social Engagement Customer and Delivery Sustainability VideoDownload ISCAR World App
