1. Flank Wear? Higher cutting resistance,Notch wear on flank, Poor roughness of surface, or deterioration of accuracy. Soft grades, Excessive cutting speed, Small flank angle, Low feed.
Select a higher, wear-resistant grade, Reduce cutting speed, Increase flank angle, Increase feed.
2. Crater Wear? Uncontrolled chip,Poor surface quality,when finishing High speed processing carbon steel
Soft grades, Excessive cutting speed, Excessive feed, The strength of chip breaker Insufficiet.
Change to a higher wear-resistant grade, Reduce cutting speed, Reduce feed, Select a higher strength chip breaker.
3. Chipping? Sudden fracture of cutting edge(rake face and flank), Instability insert life
Toughness insufficient, Excessive feed rate, Strength of cutting edge insufficient, Instability of the tool.
Select a tougher grade, Decrease feed rate, Increase honing of cutting edge(chamfering to rounding), Increase the stability and setting angle
4. Insert Fracture? Cutting resistance increased Poor surface roughness.
Toughness insufficient, Excessive feed rate, Strength of cutting edge insufficient, Instability of the tool.
Select a tougher grade, Decrease feed rate, Increase honing of cutting edge(chamfering to rounding), Increase the stability and setting angle.
5. Plastic Deformation? Variation of dimension Nose wear, cutting edge drape or passivating.when processing alloy steel Poor surface roughness
Soft grade, Excessive cutting speed, Excessive cutting depth and feed rate, Overheat on cutting edge.
Select a higher red hardness cutting material, Decrease cutting speed, Decrease cutting depth and feed rate, Select a higher thermal conductivity cutting material(CVD+sufficient coolant).
6. Build-Up-Edge? Workpiece dissove with Cutting edge Poor surface roughness when finishing, Cutting resistance increased, Cutting soft materials.
Cutting speed too low, Cutting edge obtuse, Unsuitable tool material. Increase cutting speed,Increase rake angle, Select small sticking force.
