Insert wear

​To achieve the best possible economies of tool life, workpiece quality and optimized cutting data, careful observations of the insert edge have to be made.

At low speeds, built-up edge (BUE) and chipping are the main problems; at high speeds, plastic deformation (PD), flank wear and crater wear are the problems.

​Cause

1. Cutting edge temperature too low.
2. Unsuitable geometry or grade.

Solution

1. Increase cutting speed and/or feed.
2. Choose a geometry with a sharper edges preferably a PVD-coated grade.

When parting to center in stainless material, it is almost impossible to avoid BUE. It is important to minimize this type of wear by using the solutions above.

​Cause

1. Grade too hard.
2. Geometry too weak.
3. Unstable conditions.
4. Cutting data too high.

Solution

1. Choose a softer grade.
2. Choose a geometry for higher feed area.
3. Reduce overhang. Check center height.
4. Reduce cutting data.

​Cause

1. ExceExcessive temperature in cutting zone.
2. Unsuitable grade.
3. Lack of coolant supply.

Solution

1. Reduce cutting speed and/or feed.
2. Choose more wear resistant grade.
3. Improve coolant supply.

​Cause

1. Cutting speed too high.
2. Grade too soft.
3. Lack of coolant supply.

Solution

1. Decrease cutting speed.
2. Choose more wear resistant grade.
3. Improve coolant supply.

​Cause

1. Cutting speed too high.
2. Grade too soft.
3. Feed too high.
4. Lack of coolant supply.

Solution

1. Decrease cutting speed.
2. Choose more wear resistant grade.
3. Decrease feed.
4. Improve coolant supply

​Cause

1. Oxidation at the cutting depth.
2. Cutting edge temperature too high.

Solution

1. Use varying cutting depths (ramping).
2. Reduce cutting speed.