Flank Wear

• High cutting speed
• Low wear resistance carbide grade

• 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

• Excessive cutting temperatures and pressures on the top of the insert

• 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

• Cutting temperature is too high

• Reduce cutting speed
• Use a harder material grade
• Significantly increase coolant supply

Notch Wear

• Cutting speed is too high, or insufficient insert wear resistance of the carbide grade

• 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

• Excessive variations in surface temperature, intermittent machining, or variations in coolant supply

• 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

• 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

• 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

• Cutting zone temperature is too low
• Negative cutting geometry
• Machining of very sticky materials such as low-carbon steel, stainless steels, and aluminum

• 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

• Caused by either the cutting edge of the insert being too brittle, or a built-up edge has been formed

• 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

• High cutting speed
• Low wear resistance carbide grade

• 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

• Excessive cutting temperatures and pressures on the top of the insert

• 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

• Cutting temperature is too high

• Reduce cutting speed
• Use a harder material grade
• Reduce the feed rate

Thermal Cracking

• Excessive variations in surface temperature, intermittent machining, or variations in coolant supply

• 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

• 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

• Reduce cutting speed
• Use endmills of chatter-free geometry
• Use a tougher cutting tool material grade

Built-up Edge

• Cutting zone temperature is too low
• Negative cutting geometry
• Machining of very sticky materials such as low-carbon steel, stainless steels, and aluminum

• Increase cutting speed
• Significantly increase coolant supply
• Use inserts, produced from a tool material grade with a post coating treatment