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    Milling Inserts Wear Problems and Solutions

    MILLING - INDEXABLE INSERTS
    MILLING -
    SOLID CARBIDE AND
    MULTI-MASTER


    Type of Wear
      • ×
        Flank Wear
        Flank Wear
        Cause
        • High cutting speed
        • Low wear resistance carbide grade

        Remedy
        • Reduce cutting speed
        • Use a more wear- resistant cutting tool material grade
        • Select a more wear resistant grade
        • For work-hardening materials, select a smaller entry angle
        • Reduce the cutting speed when machining heat resistant materials
      • ×
        Crater Wear
        Crater Wear
        Cause
        • Excessive cutting temperatures and pressures on the top of the insert

        Remedy
        • Reduce cutting speed
        • Reduce feed
        • Use a tool with more positive geometry
        • Use a harder material grade
        • Select a more wear resistant grade
        • Select a more positive insert geometry
        • Reduce the cutting speed or reduce the feed rate to lower the temperature
        • Use higher coolant flow and pressure, consider High pressure coolant
      • ×
        Plastic Deformation
        Plastic Deformation
        Cause
        • Cutting temperature is too high

        Remedy
        • Reduce cutting speed
        • Use a harder material grade
        • Significantly increase coolant supply
      • ×
        Notch Wear
        Notch Wear
        Cause
        • Cutting speed is too high, or insufficient insert wear resistance of the carbide grade

        Remedy
        • Use more wear resistant tool material grade
        • Reduce cutting speed
        • Vary cutting depth
        • Use insert with a reinforced cutting edge geometry
        • For work-hardening materials, select a smaller entry angle
        • Reduce the cutting speed when machining heat resistant materials
      • ×
        Thermal Cracking
        Thermal Cracking
        Cause
        • Excessive variations in surface temperature, intermittent machining, or variations in coolant supply

        Remedy
        • Reduce cutting speed
        • Use tougher cutting tool material grade
        • Significantly increase coolant supply or turn it off
        • Eliminate the use of coolant whenever possible
      • ×
        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
        • Use inserts with larger corner radius / chamfer, preferrably single-sided
        • Use cutters of chatter-free geometry
        • Use a tougher cutting tool material grade
        • Reduce feed
        • Apply vibration-dampening toolholders
      • ×
        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 cutting speed
        • Use cutters with more positive rake angle and sharper cutting edge
        • Significantly increase coolant supply
        • Use inserts, produced from a tool material grade with a post coating treatment
      • ×
        Chipping
        Chipping
        Cause
        • Caused by either the cutting edge of the insert being too brittle, or a built-up edge has been formed

        Remedy
        • Use inserts, produced from a tougher tool material grade
        • Use inserts with reinforced cutting edge
        • Increase cutting speed
        • Apply cutters with chatter-free geometry
        • Apply vibration-dampening toolholders
      • ×
        Flank Wear
        Flank Wear
        Cause
        • High cutting speed
        • Low wear resistance carbide grade

        Remedy
        • Reduce cutting speed
        • Use a more wear- resistant cutting tool material grade
        • Select a more wear resistant grade
        • For work-hardening materials, select a smaller entry angle
        • Reduce the cutting speed when machining heat resistant materials
      • ×
        Crater Wear
        Crater Wear
        Cause
        • Excessive cutting temperatures and pressures on the top of the insert

        Remedy
        • Reduce cutting speed
        • Reduce feed
        • Use a tool with more positive geometry
        • Use a harder material grade
        • Select a more wear resistant grade
        • Select a more positive insert geometry
        • Reduce the cutting speed or reduce the feed rate to lower the temperature
        • Use higher coolant flow and pressure, consider High pressure coolant
      • ×
        Plastic Deformation
        Plastic Deformation
        Cause
        • Cutting temperature is too high

        Remedy
        • Reduce cutting speed
        • Use a harder material grade
        • Reduce the feed rate
      • ×
        Thermal Cracking
        Thermal Cracking
        Cause
        • Excessive variations in surface temperature, intermittent machining, or variations in coolant supply

        Remedy
        • Reduce cutting speed
        • Use tougher cutting tool material grade with higher thermal resistance
        • Significantly increase coolant supply or turn it off
        • Select a tougher insert grade
        • Eliminate the use of coolant whenever possible
      • ×
        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 endmills of chatter-free geometry
        • Use a tougher cutting tool material grade
      • ×
        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 cutting speed
        • Significantly increase coolant supply
        • Use inserts, produced from a tool material grade with a post coating treatment
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