Insert Wear Problems and Solutions

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切断&切槽 > Face Turning / Grooving > PENTACUT

钻削刀片磨损原因及解决方案

整体硬质合金钻头

可换头式钻头

可换刀片式钻头

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
  - 检查所用刀具形状是否正确
  - 提高冷却液压力
  - 更换为硬度更高的牌号
  - 提高冷却液里油浓度百分比
  - 降低切削速度。***提高进给
- ×
  
  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
  - 降低进给
  - 检查所用刀具形状是否正确
- ×
  
  塑性变形
  塑性变形
  
  原因
  - 切削温度过高
  解决方案
  - 检查切削参数
  - 降低进给
  - 提高冷却液压力 / 冷却液流量
  - 采用硬度更高的牌号
  - 检查所用刀具形状是否正确
- ×
  
  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
  - 提高冷却液压力 / 冷却液流量
  - 提高冷却液中油含量百分比
- ×
  
  切削刃外侧破损
  切削刃外侧破损
  
  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
  解决方案
  - 检查钻头径向跳动
  - 降低进给率，提高切削速度
  - 检查刀具及工件的夹持刚性
  - 检查定位槽夹持力是否过低，更换钻杆
  - 提高冷却液压力
  - 采用外冷加工时，调整冷却射流方向使其更精准
- ×
  
  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
  - 提高进给
  - 提高切削速度
  - 提高冷却液压力
  - 检查冷却液中油含量百分比
- ×
  
  切削刃崩刃
  切削刃崩刃
  
  原因
  - 硬质合金牌号不耐磨
  - 刀片已形成了积屑瘤
  - 切削液供应不足
  解决方案
  - 降低进给率
  - 提高切削速度
  - 提高冷却液压力
  - 采用外冷加工时，调整冷却射流方向使其更精准
  - 更换为不同形状的钻头
  - 检查刀具及工件的夹持刚性
- ×
  
  横刃崩刃
  横刃崩刃
  
  原因
  - 横刃跳动太大
  - 结合了高进给 & 低切削速度
  解决方案
  - 降低进给率并提高切削速度
  - 检查横刃错位不超过0.02mm
  - 检查刀具及工件的夹持刚性
  - 检查定位槽夹持力是否过低，更换钻杆
- ×
  
  切削刃外侧崩刃
  切削刃外侧崩刃
  
  原因
  - 径向跳动太大
  - 切削液供应不足
  解决方案
  - 检查钻头径向跳动
  - 降低进给率，提高切削速度
  - 检查刀具及工件的夹持刚性
  - 检查定位槽夹持力是否过低，更换钻杆
  - 提高冷却液压力
  - 采用外冷加工时，调整冷却射流方向使其更精准
- ×
  
  棱边磨损
  棱边磨损
  
  原因
  - 切削速度过高
  - 硬质合金牌号不耐磨
  - 径向跳动太大
  解决方案
  - 检查所用刀具形状是否正确
  - 检查刀尖跳动T.I.R不超过0.02mm
  - 降低切削速度
  - 提高冷却液压力
  - 采用外冷加工时，调整冷却射流方向使其更精准
  - 检查并提高刀具及工件的夹持刚性
  - 检查定位槽夹持力是否过低，更换钻杆
- ×
  
  Flank Wear
  Flank Wear
  
  原因
  - High cutting speed
  - Low wear resistance carbide grade
  Remedy
  - Check that the correct geometry is used
  - Increase coolant pressure
  - Change to harder grade
  - Increase oil concentration presentage
  - Reduce cutting speed.*** increase feed
- ×
  
  Crater Wear
  Crater Wear
  
  原因
  - Excessive cutting temperatures and pressures on the top of the insert.
  Remedy
  - Reduce cutting feed
  - Check that the correct geometry is used
- ×
  
  Plastic Deformation
  Plastic Deformation
  
  原因
  - Cutting temperature is too high
  Remedy
  - Check cutting parameters
  - Reduce cutting feed
  - Increase coolant pressure/volume
  - Use harder grade
  - Check that the correct geometry is used
- ×
  
  Thermal Cracking
  Thermal Cracking
  
  原因
  - Excessive variations in surface temperature, intermittent machining, or variations in coolant supply
  Remedy
  - Increase coolant pressure/volume
  - Increase oll concentration presentage
- ×
  
  Corner Fracture
  Corner Fracture
  
  原因
  - 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
  - Check radial run-out
  - Reduce feed rate increase the speed
  - Check tool and part clamping rigidity
  - Check if pocket gripping forces is too low, replace the holder
  - Increase coolant pressure
  - Improve jet direction in case of external coolant supply
- ×
  
  Built-up Edge
  Built-up Edge
  
  原因
  - 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 feed
  - Increase cutting speed
  - Increase coolant pressure
  - Check oil percentage in the coolant fluid
- ×
  
  Edge chipping
  Edge chipping
  
  原因
  - Low wear resistance carbide grade
  - Built-up edge has been formed
  - Insufficient cutting fluid
  Remedy
  - Reduce feed rate
  - Increase the speed
  - Increase coolant pressure
  - Improve jet direction in case of external coolant supply
  - Change to different geometry
  - Check tool and part clamping rigidity
- ×
  
  Chisel Chipping
  Chisel Chipping
  
  原因
  - Chisel run-out is too big
  - Combine of high feed & low speed
  Remedy
  - Reduce feed rate and increase the cutting speed
  - Check that chisel misalignment does not exceed 0.02mm
  - Check tool and part clamping rigidity
  - Check if pocket gripping forces is too low, replace the holder
- ×
  
  Land Wear
  Land Wear
  
  原因
  - Cutting speed too high
  - Low wear resistance carbide grade
  - Radial run-out is too big
  Remedy
  - Check that the correct geometry is used
  - Check that T.I.R run-out does not exceed 0.02mm
  - Reduce cutting speed
  - Increase coolant pressure
  - Improve jet direction in case of external coolant supply
  - Check and improve tool and part clamping rigidity
  - Check if pocket gripping forces is too low, replace the tool body
- ×
  
  Corner Chipping
  Corner Chipping
  
  原因
  - Radial run-out is too big
  - Insufficient cutting fluid
  Remedy
  - Check radial run-out
  - Reduce feed rate increase the speed
  - Check tool and part clamping rigidity
  - Check if pocket gripping forces is too low, replace the holder
  - Increase coolant pressure
  - Improve jet direction in case of external coolant supply
- ×
  
  Flank Wear
  Flank Wear
  
  Cause
  - High cutting speed
  - Low wear resistance carbide grade
  Remedy
  - Reduce cutting speed
  - Increase coolant pressure/volume
  - Choose better wear resistance grade
  - Increase oil concentration presentage
- ×
  
  Crater Wear
  Crater Wear
  
  Cause
  - Excessive cutting temperatures and pressures on the top of the insert
  Remedy
  outer insert:
  - Reduce cutting speed
  - Choose better wear resistance grade
  - Change to different chipbreaker
  inner insert:
  - Reduce feed rate
  - Change to different chipbreaker
- ×
  
  Plastic Deformation
  Plastic Deformation
  
  Cause
  - Cutting temperature is too high
  Remedy
  - Reduce feed rate
  - Choose better wear resistance grade
  - Increase coolant pressure/volume
  - Choose diferent chip-breaker
- ×
  
  Thermal Cracking
  Thermal Cracking
  
  Cause
  - Excessive variations in surface temperature, intermittent machining, or variations in coolant supply
  Remedy
  - Use tougher grade
  - Increase coolant pressure/volume
- ×
  
  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 tougher grade
  - Reduce feed rate
  - Increase coolant pressure/volume
  - Change to different chipbreaker
- ×
  
  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
  - Change to different chipbreaker
  - Reduce feed rate
  - Increase coolant pressure/volume
- ×
  
  Chipping
  Chipping
  
  Cause
  - Low wear resistance carbide grade
  - Built-up edge has been formed
  - Insufficient cutting fluid
  Remedy
  - Choose tougheer grade
  - Reduce feed
  - Increase coolant pressure/volume
  - Change to different chipbreaker