Insert Wear Problems and Solutions

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车削-切槽刀片 & 切断刀片磨损原因及解决方案

车削-切槽刀片

切断

端面切槽

磨损类型

- ×
  
  后刀面磨损
  后刀面磨损
  
  原因
  - 切削速度高
  - 硬质合金牌号不耐磨
  解决方案
  - 降低切削速度
  - 采用耐磨性更佳的牌号
  - 提高冷却液压力
  - 调整刀片中心高度
- ×
  
  月牙洼磨损
  月牙洼磨损
  
  原因
  - 刀片切削区域切削温度过高，压力过大
  解决方案
  - 降低切削速度
  - 降低进给率
  - 采用耐磨性更佳的牌号
  - 提高冷却液压力
  - 采用带大正前角的刀片
- ×
  
  塑性变形
  塑性变形
  
  原因
  - 切削温度过高
  解决方案
  - 降低切削速度
  - 降低进给率
  - 采用耐磨性更佳的牌号
  - 提高冷却液压力
- ×
  
  沟槽磨损
  沟槽磨损
  
  原因
  - 切削速度过高，或刀片牌号不耐磨
  解决方案
  - 降低切削速度
  - 降低进给率
  - 采用耐磨性更佳的牌号
  - 调整切削深度
  - 提高冷却液压力
- ×
  
  热裂
  热裂
  
  原因
  - 切削区域表面温度变化太大，断续切削，或冷却液供应产生变化
  解决方案
  - 降低切削速度
  - 降低进给率
  - 采用韧性更佳的牌号
  - 采用更强固的切削刃
  - 断续切削时停止供应冷却液
- ×
  
  切削刃破损
  切削刃破损
  
  原因
  - 更换刀片切削刃前，刀片过度磨损
  - 对于该应用而言，刀片牌号及几何形状都太弱了
  - 刀片载荷过大
  - 刀片已形成了积屑瘤
  原因
  - 降低切削速度
  - 采用韧性更佳的牌号
  - 降低进给率
  - 采用更强壮的刀体
  - 采用更强固的负前角刀片
  - 采用螺钉夹持式替代自夹式
  - 调整刀片中心高度
  - 减小刀具悬伸
- ×
  
  积屑瘤
  积屑瘤
  
  原因
  - 切削区域温度太低
  - 负型刀片
  - 加工材料粘性高，如低碳钢，不锈钢及铝
  解决方案
  - 提高切削速度
  - 采用带锋利切削刃的可转位刀片
  - 提高冷却液压力
- ×
  
  Flank Wear
  Flank Wear
  
  Cause
  - High cutting speed
  - Low wear resistance carbide grade
  Remedy
  - Reduce cutting speed
  - Use harder grade
  - Increase coolant pressure
  - Adjust center height position
- ×
  
  Crater Wear
  Crater Wear
  
  Cause
  - Excessive cutting temperatures and pressures on the top of the insert.
  Remedy
  - Use harder grade
  - Reduce cutting speed
  - Increase coolant pressure
  - Use an insert with a positive cutting rake
- ×
  
  Plastic Deformation
  Plastic Deformation
  
  Cause
  - Cutting temperature is too high
  Remedy
  - Use harder grade
  - Reduce feed rate
  - Reduce cutting speed
  - Increase coolant pressure
- ×
  
  Notch Wear
  Notch Wear
  
  Cause
  - Cutting speed too high, or insufficient insert wear resistance of the carbide grade
  Remedy
  - Reduce the cutting speed
  - Use harder grade
  - Use reinforced cutting edge negative cutting rake
  - Adjust center height position
  - Increase the coolant pressure
- ×
  
  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 grade
  - Use stronger edge geometry
  - Turn off coolant supply when machining interrupted cuts
- ×
  
  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
  - Reduce the cutting speed
  - Use tougher grade
  - Reduce feed rate
  - Reduce tool extension
  - Use more stable tool holder
  - Use reinforced cutting edge negative cutting rake
  - Use screw clamping instead of self clamping
  - Check center height position
  - Use screw clamping instead of self- clamping
- ×
  
  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 the cutting speed
  - Use an insert with a positive cutting rake
  - Increase the coolant pressure
- ×
  
  Flank Wear
  Flank Wear
  
  Cause
  - High cutting speed
  - Low wear resistance carbide grade
  Remedy
  - Reduce cutting speed
  - Use harder grade
  - Increase coolant pressure
  - Adjust center height position
- ×
  
  Crater Wear
  Crater Wear
  
  Cause
  - Excessive cutting temperatures and pressures on the top of the insert.
  Remedy
  - Use harder grade
  - Reduce cutting speed
  - Increase coolant pressure
  - Use an insert with a positive cutting rake
- ×
  
  Plastic Deformation
  Plastic Deformation
  
  Cause
  - Cutting temperature is too high
  Remedy
  - Use harder grade
  - Reduce feed rate
  - Reduce cutting speed
  - Increase coolant pressure
- ×
  
  Notch Wear
  Notch Wear
  
  Cause
  - Cutting speed too high, or insufficient insert wear resistance of the carbide grade
  Remedy
  - Reduce the cutting speed
  - Use harder grade
  - Use reinforced cutting edge negative cutting rake
  - Adjust center height position
  - Increase the coolant pressure
- ×
  
  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 grade
  - Use stronger edge geometry
  - Turn off coolant supply when machining interrupted cuts
- ×
  
  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
  - Reduce cutting speed
  - Use tougher grade
  - Reduce feed rate
  - Reduce tool extension
  - Use more stable tool holder
  - Use reinforced cutting edge negative cutting rake
  - Check center height
  - Use screw clamping instead of self- clamping
- ×
  
  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 the cutting speed
  - Use an insert with a positive cutting rake
  - Increase the coolant pressure

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车削-切槽刀片 & 切断刀片磨损原因及解决方案

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车削-切槽刀片 & 切断刀片磨损原因及解决方案

关于我们 ▼

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Company ▼

News & Publications ▼

ISCAR Sustainability ▼

Download ISCAR World App

关于我们

产品分类

Company

News & Publications

ISCAR Sustainability