CNC Knowledge: Do you know how to judge and manage cutting blade wear?

In order to achieve better cutting quality and the longest possible tool life, we need to check the blade after processing, summarize the causes of different forms of blade wear and find solutions, this which forms the basis for successful milling.

Sidewall wear 1

Rapid wear results in poor surface quality or out-of-tolerance surfaces.

reason

Cutting speed too high

Insufficient wear resistance

The fz power supply is too low

solution

Reduce cutting speed (vc)

Choose materials with greater wear resistance

Increase power (fz)

Sidewall wear 2

Excessive wear results in short tool life.

reason

vibration

chip cutting

Burrs form on parts

Poor surface quality

generate heat

solution

Increase power (fz)

Use down milling

Effective chip removal using compressed air

Check recommended cutting settings

Sidewall wear 3

Uneven wear leads to damage to sharp corners.

reason

Tool runout

vibration

Short lifespan

Poor surface quality

Noisy

Radial force too high

solution

Reduce runout to less than 0.02mm

Check clips and jackets

Minimize tool protrusion

Use fewer teeth to cut

Choose a larger tool diameter

For solid carbide cutters and interchangeable head cutters, choose a geometry with a larger helix angle (gp≥45°)

Divide the axial depth of cut (ap) into several passes

Reduce power (fz)

Reduce cutting speed (vc)

High-speed machining requires shallow tool passes

Improved tool and workpiece clamping

crater wear

Excessive wear results in reduced cutting edge strength. Broken cutting edges result in poor surface quality.

reason

Diffusion wear due to excessive cutting temperature on the rake face

solution

Choose Aluminum Oxide Coating Material

Choose a positive rake angle insert geometry

Reduce speed to get lower temperatures, then reduce power

plastic deformation

Plastic deformation, collapse or sinking of the cutting edge flanks results in poor chip control, poor surface quality and insert breakage.

reason

Cutting temperature and pressure are too high

solution

Choose a material with higher wear resistance (harder)

Reduce cutting speed (vc)

Reduce power (fz)

broken blade 1

The part of the cutting edge that is not involved in cutting is damaged by chip hammering. Damage to the front face and seating surfaces of the insert, resulting in poor surface texture and excessive sidewall wear.

reason

The chips are crushed by the cutting edge

solution

Choose a shade with higher tenacity

Choose an insert with a stronger edge

Increase cutting speedvc

Choose a positive cutting geometry

Reduce the feed at the start of the cut

Improve stability

broken blade 2

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

reason

The toughness of the material is too low

The geometry of the insert is too weak

built edge

solution

Choose a shade with higher tenacity

Choose an insert with stronger geometry

Increase cutting speed vc or choose positive rake angle geometry

Reduce the feed at the start of the cut

Groove wear

Groove wear leads to poor surface quality and a risk of cutting edge breakage.

reason

Work hardened materials

epidermis and oxide tartar

solution

Reduce cutting speed (vc)

Choose a shade with higher tenacity

Use stronger geometry

Use a cutting angle closer to 45°

Use round blades to ensure the best results

Delay wear with variable ap technology

hot cracks

Small cracks perpendicular to the cutting edge due to temperature changes lead to chipping and poor surface quality.

reason

Intermittent treatment

Changing the cutting fluid supply

solution

Choose materials with higher toughness and better thermal shock resistance

Cutting fluid should be used in sufficient quantity, if at all.

Built-in edge 1

Built-up edges result in poor surface quality and cause the cutting edge to chip when it breaks.

reason

Cutting zone temperature is too low

Very high viscosity materials such as mild steel, stainless steel and aluminum

solution

Increase cutting speedvc

Switching to a more suitable insert geometry

Added edge 2

The workpiece material is welded to the cutting edge.

reason

low cutting speed vc

low feed fz

Negative rake angle cutting geometry

Poor surface quality

solution

Increase cutting speedvc

Increase power fz

Choose a positive cutting geometry

Use oil mist or cutting fluid