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车削-切槽刀片 & 切断刀片磨损原因及解决方案

车削-切槽刀片
切断
端面切槽

磨损类型
    • ×
      后刀面磨损
      后刀面磨损
      原因
      • 切削速度高
      • 硬质合金牌号不耐磨

      解决方案
      • 降低切削速度
      • 采用耐磨性更佳的牌号
      • 提高冷却液压力
      • 调整刀片中心高度
    • ×
      月牙洼磨损
      月牙洼磨损
      原因
      • 刀片切削区域切削温度过高，压力过大

      解决方案
      • 降低切削速度
      • 降低进给率
      • 采用耐磨性更佳的牌号
      • 提高冷却液压力
      • 采用带大正前角的刀片
    • ×
      塑性变形
      塑性变形
      原因
      • 切削温度过高

      解决方案
      • 降低切削速度
      • 降低进给率
      • 采用耐磨性更佳的牌号
      • 提高冷却液压力
    • ×
      沟槽磨损
      沟槽磨损
      原因
      • 切削速度过高，或刀片牌号不耐磨

      解决方案
      • 降低切削速度
      • 降低进给率
      • 采用耐磨性更佳的牌号
      • 调整切削深度
      • 提高冷却液压力
    • ×
      热裂
      热裂
      原因
      • 切削区域表面温度变化太大，断续切削，或冷却液供应产生变化

      解决方案
      • 降低切削速度
      • 降低进给率
      • 采用韧性更佳的牌号
      • 采用更强固的切削刃
      • 断续切削时停止供应冷却液
    • ×
      切削刃破损
      切削刃破损
      原因
      • 更换刀片切削刃前，刀片过度磨损
      • 对于该应用而言，刀片牌号及几何形状都太弱了
      • 刀片载荷过大
      • 刀片已形成了积屑瘤

      原因
      • 降低切削速度
      • 采用韧性更佳的牌号
      • 降低进给率
      • 采用更强壮的刀体
      • 采用更强固的负前角刀片
      • 采用螺钉夹持式替代自夹式
      • 调整刀片中心高度
      • 减小刀具悬伸
    • ×
      积屑瘤
      积屑瘤
      原因
      • 切削区域温度太低
      • 负型刀片
      • 加工材料粘性高，如低碳钢，不锈钢及铝

      解决方案
      • 提高切削速度
      • 采用带锋利切削刃的可转位刀片
      • 提高冷却液压力
    • ×
      Flank Wear
      Flank Wear
      Cause
      • High cutting speed
      • Low wear resistance carbide grade

      Remedy
      • Reduce cutting speed
      • Use harder grade
      • Increase coolant pressure
      • Adjust center height position
    • ×
      Crater Wear
      Crater Wear
      Cause
      • Excessive cutting temperatures and pressures on the top of the insert.

      Remedy
      • Use harder grade
      • Reduce cutting speed
      • Increase coolant pressure
      • Use an insert with a positive cutting rake
    • ×
      Plastic Deformation
      Plastic Deformation
      Cause
      • Cutting temperature is too high

      Remedy
      • Use harder grade
      • Reduce feed rate
      • Reduce cutting speed
      • Increase coolant pressure
    • ×
      Notch Wear
      Notch Wear
      Cause
      • Cutting speed too high, or insufficient insert wear resistance of the carbide grade

      Remedy
      • Reduce the cutting speed
      • Use harder grade
      • Use reinforced cutting edge negative cutting rake
      • Adjust center height position
      • Increase the coolant pressure
    • ×
      Thermal Cracking
      Thermal Cracking
      Cause
      • Excessive variations in surface temperature, intermittent machining, or variations in coolant supply

      Remedy
      • Reduce cutting speed
      • Reduce feed rate
      • Use tougher grade
      • Use stronger edge geometry
      • Turn off coolant supply when machining interrupted cuts
    • ×
      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 the cutting speed
      • Use tougher grade
      • Reduce feed rate
      • Reduce tool extension
      • Use more stable tool holder
      • Use reinforced cutting edge negative cutting rake
      • Use screw clamping instead of self clamping
      • Check center height position
      • Use screw clamping instead of self- clamping
    • ×
      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 the cutting speed
      • Use an insert with a positive cutting rake
      • Increase the coolant pressure
    • ×
      Flank Wear
      Flank Wear
      Cause
      • High cutting speed
      • Low wear resistance carbide grade

      Remedy
      • Reduce cutting speed
      • Use harder grade
      • Increase coolant pressure
      • Adjust center height position
    • ×
      Crater Wear
      Crater Wear
      Cause
      • Excessive cutting temperatures and pressures on the top of the insert.

      Remedy
      • Use harder grade
      • Reduce cutting speed
      • Increase coolant pressure
      • Use an insert with a positive cutting rake
    • ×
      Plastic Deformation
      Plastic Deformation
      Cause
      • Cutting temperature is too high

      Remedy
      • Use harder grade
      • Reduce feed rate
      • Reduce cutting speed
      • Increase coolant pressure
    • ×
      Notch Wear
      Notch Wear
      Cause
      • Cutting speed too high, or insufficient insert wear resistance of the carbide grade

      Remedy
      • Reduce the cutting speed
      • Use harder grade
      • Use reinforced cutting edge negative cutting rake
      • Adjust center height position
      • Increase the coolant pressure
    • ×
      Thermal Cracking
      Thermal Cracking
      Cause
      • Excessive variations in surface temperature, intermittent machining, or variations in coolant supply

      Remedy
      • Reduce cutting speed
      • Reduce feed rate
      • Use tougher grade
      • Use stronger edge geometry
      • Turn off coolant supply when machining interrupted cuts
    • ×
      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 tougher grade
      • Reduce feed rate
      • Reduce tool extension
      • Use more stable tool holder
      • Use reinforced cutting edge negative cutting rake
      • Check center height
      • Use screw clamping instead of self- clamping
    • ×
      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 the cutting speed
      • Use an insert with a positive cutting rake
      • Increase the coolant pressure