Do You Know How To Judge And Handle The Wear of The Cutting Blades During Machining?

In order to achieve better quality cutting and maximize tool life, we need to inspect the blades after machining, summarize the causes of different forms of blade wear, and find solutions, which are the foundation of successful milling.

Rear blade wear 1

Rapid wear leading to poor surface quality or exceeding tolerance range

reason

Cutting speed too high

Insufficient wear resistance

Feed fz too low

Solution

Reduce cutting speed (VC)

Choose materials with higher wear resistance

Increase feed rate (fz)

Rear blade wear 2

Excessive wear leads to short tool life.

reason

vibration

Chip re cutting

Burrs formed on the parts

Poor surface quality

Generating heat

Solution

Increase feed rate (fz)

Using forward milling

Effective chip removal using compressed air

Check the recommended cutting parameters

Rear blade wear 3

Uneven wear leads to sharp corner damage.

Tool jumping

vibration

Short tool life

Poor surface quality

High noise level

Excessive radial force

Solution

Reduce the runout to less than 0.02mm

Check the collet and sleeve

Minimize tool extension to the greatest extent possible

Using fewer teeth for cutting

Choose a larger tool diameter

For integral hard alloy end mills and interchangeable end mills, choose groove shapes with larger helix angles (gp ≥ 45 °)

Divide the axial cutting depth (ap) into multiple cutting paths

Reduce feed (fz)

Reduce cutting speed (VC)

High speed machining requires shallow cutting

Improving the clamping of cutting tools and workpieces

crater wear

Excessive wear leads to a decrease in cutting edge strength. Cutting edge damage leads to poor surface quality.

reason

Diffusion wear caused by high cutting temperature on the front cutting surface

Solution

Choose aluminum oxide coating material

Select the groove shape of the front corner blade

Reduce speed to achieve lower temperature, and then decrease feed rate

Plastic deformation

Plastic deformation, collapse, or indentation of the cutting edge can lead to poor chip control, poor surface quality, and blade fracture.

reason

Cutting temperature and pressure too high

Solution

Choose materials with higher wear resistance (hardness)

Reduce cutting speed (VC)

Reduce feed (fz)

Broken Blade 1

The part of the cutting edge that is not involved in cutting is damaged due to chip hammer impact. The front and support surfaces of the blade are damaged, resulting in poor surface texture and excessive wear on the rear blade surface.

reason

Chips are compressed under the action of the cutting edge

Solution

Choose a brand with higher toughness

Choose a blade with a stronger cutting edge

Increase cutting speed VC

Select front corner groove type

Reduce feed at the beginning of cutting

Improve stability

Broken Blade 2

A small portion of the cutting edge breaks (shatters), resulting in poor surface quality and excessive wear on the rear cutting surface.

reason

The material toughness is too low

The blade groove is too weak

Generating debris tumors

Solution

Choose a brand with higher toughness

Choose blades with stronger groove shapes

Increase cutting speed VC, or choose a positive rake groove type

Reduce feed at the beginning of cutting

Groove wear

The wear of grooves leads to poor surface quality and the risk of cutting edge fracture.

reason

Work hardening materials

Epidermis and oxide skin

Solution

Reduce cutting speed (VC)

Choose a brand with higher toughness

Use a more sturdy groove shape

Using a cutting angle closer to 45 °

Use circular blades to ensure optimal results

Using variable AP technology to delay wear

Hot cracking

Due to temperature changes, small cracks perpendicular to the cutting edge cause fragmentation and poor surface quality.

reason

Intermittent processing

Changing cutting fluid supply

Solution

Choose materials with higher toughness and better thermal shock resistance

Sufficient or no cutting fluid should be used at all

Smegma 1

The accumulation of chips leads to poor surface quality and causes the cutting edge to shatter when falling off.

reason

Cutting area temperature too low

Materials with very high viscosity, such as low-carbon steel, stainless steel, and aluminum

Solution

Increase cutting speed VC

Change to a more suitable blade groove type

Smegma 2

The workpiece material is welded onto the cutting edge.

reason

Low cutting speed VC

Low feed fz

Negative front angle cutting groove

Poor surface quality

Solution

Increase cutting speed VC

Increase feed fz

Select front corner groove type

Use oil mist or cutting fluid