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Uniform flank wear

One of the most common wear types (typical for dry ISO-P). Usually starts on the cutting edge and develops more towards the flank side of cutting edge.

Main wear mechanism - abrasive

Cause:

• High cutting speed and low feed
• Low wear resistance

Non-uniform flank wear

Initially, some parts of the cutting edge are worn faster than others.

Main wear mechanism - partial flaking of coating and irregular micro-chipping on the cutting edge followed by abrasive wear.

Cause:

• High cutting speed and low feed
• Vibrations
• Low wear resistance

Localized flank wear

Usually on tool corners and/or at maximum depth of cut.

Main wear mechanisms - adhesive, thermomechanical or chemical.

Cause:

• High temperature
• Vibrations
• Chip re-cutting

Crater wear

Rarely seen on solid end mills.

Main wear mechanisms – chemical and abrasive.

Cause:

• High temperature (high cutting speed)

Stair-formed face wear

Usually occurs when flood (low pressure) coolant is supplied through external nozzles.

Main wear mechanism – chemical

Cause:

• High temperature

Flaking

Usually when milling materials which are easily smearing to the cutting edge.

Main wear mechanism – adhesive

Cause:

• Sticky workpiece material

Uniform chipping (frittering)

Minor damages of the cutting edge. Other wear types can be followed by chipping.

Main wear mechanisms – thermomechanical or adhesive

Cause:

• Cutting edge is too weak and brittle
• Excessive temperature fluctuations
• Vibrations

Comb cracks

Appears on cutting edge and extends on rake and flank faces. Initially oriented perpendicularly to the cutting edge, forms lateral cracks and provoke edge chipping.Main wear mechanism – thermomechanical

Cause:

• Rapid fluctuations in temperature

Localized chipping

Damage occurs consistently at certain position along the cutting edge line.

Main wear mechanisms – thermomechanical or adhesive

Cause:

• Cutting edge is too weak and brittle
• Excessive temperature fluctuations
• Vibrations

Chip re-cutting

Non-uniform chipping

Damage of the cutting edge irregularly positioned along the cutting edge line.

Main wear mechanisms – thermomechanical or adhesive

Cause:

• Cutting edge is too weak and brittle
• Excessive temperature fluctuations
• Vibrations
• Chip re-cutting
• Remedy

Top slicing

Usually when milling ISO-S materials. Starts on the edge line, extends to rake face and forms top slices.

Main wear mechanisms – adhesive and brittle fracturing

Cause:

• Sticky workpiece material
• High temperature
• Vibrations