Académique Documents
Professionnel Documents
Culture Documents
1
Categories of Tool Failure
Abrasive Wear Flank Wear
Chipping
(Flank Chipping)
Mechanical (Rake Face Chipping)
Failure Depth-of-Cut Notching
Fracture
Built Up Edge
Rake Surface
Flank Surface
Heat Failure Thermal Cracking
Crater Wear
Thermal Deformation
2
Flank
Wear
Insert Drill
Trailing edge
4
Wear Land
5
Useable life
of the tool
0.025 (0.635)
0.020 (0.508)
WEAR IN. (MM)
0.015 (0.381)
0.010 (0.254)
0.005 (0.128)
0.000
0 5 10 15 20 25
TIME
6
Flank
Wear
7
Mechanical
Failure
Chipping
Notching
Fracture
8
Chipping
Flank Chipping
Rake Face Chipping
9
Mechanical Chipping
(Flank chipping)
Cutting Forces
10
Small Chip on
Rake Surface
Large Chip on
Flank Surface
Flank Chipping
(Mechanical)
11
Rake Face Chipping
(Thermal Expansion)
FORCE HEAT
Inadequate
Clearance
12
Rake Face Chipping Due to Thermal
Expansion and Radial Cutting Forces
14
DOC Notching
15
Depth-of-Cut
Notching
17
Fracture
18
Fracture
Chipping or breakage
Common in interrupted cuts
and in non-rigid setups
Many potential causes;
good application practices are essential
19
Minimizing Fracture--
Chipping and Breakage
Tougher cutting tool material:
Cobalt enriched grades
higher cobalt
TiC, & TaC, bearing grades
Stronger geometry
Maximize rigidity
20
Heat Related
Failure
Built Up Edge
Thermal Cracking
Cratering
Thermal Deformation
21
Built Up Edge
22
Built-Up Edge
23
Rake Face
Built up Edge
Welding of workpieces
material to the rake face of
the cutting tool. Loss of
effective geometry causes
increases in cutting forces
and eventual tool breakage.
24
Minimizing Rake Face
Built Up Edge
25
Flank Face
Built up Edge
26
Thermal-Mechanical
Cracking
27
Thermal Cracking
Evenly-spaced cracks
perpendicular to the edge
Commonly observed in
milling
and interrupted cutting
Caused by thermal shock
cycling -- repeated heating
and cooling of the edge
28
Minimizing
Thermal Cracking
Tougher, more thermal-shock-resistant
tool material
Use a grade with more TaC content
Higher cobalt content carbide grade
Avoid coolant if possible
or assure a steady supply
29
Cratering
30
Cratering
Insert Drill
32
Thermal
Deformation
33
Thermal
Deformation
35