Техническая информация Sumitomo - страница 4

Tool Failure and Remedies

■ Insert Failure and Countermeasures

Type of Insert Failure

Flank Wear

Cause Countermeasures

• Grade lacks wear resistance.
• Select a more wear-resistant grade. P30 → P20 → P10 K20 → K10 → K01
• Use an insert with a larger rake angle.
• Cutting speed is too fast.
• Decrease the cutting speed
• Feed rate is far too slow.
• Increase feed rates.

Crater Wear

Chipping

Fracture

Welding or Built-up Edge

Plastic Deformation

N

Notch Wear

• Grade lacks crater wear resistance.
• Select a more crater-wear-resistant grade.
• Rake angle is too small.
• Use an insert with a larger rake angle.
• Change the chipbreaker.
• Cutting speed is too fast.
• Decrease the cutting speed
• Feed rate and depth of cut are too
• Reduce feed rates and depth of cut.

large.

• Grade lacks toughness.
• Select a tougher grade. P10 → P20 → P30
• Cutting edge breaks off due to chip build-up. K01 → K10 → K20
• Cutting edge lacks toughness.
• Increase amount of honing on cutting edge.
• Reduce rake angle.
• Feed rate and depth of cut are too
• Reduce feed rates and depth of cut.

large.

• Grade lacks toughness.
• Select a tougher grade. P10 → P20 → P30 K01 → K10 → K20
• Cutting edge lacks toughness.
• Select a chipbreaker with a strong cutting edge.
• Holder lacks toughness.
• Select a holder with a larger approach angle.
• Select a holder with a larger shank size.
• Feed rate is too fast.
• Reduce feed rates and depth of cut.
• Depth of cut is too large.
• Inappropriate grade selection.
• Select a grade with less affinity to the work material like coated carbide or cermet grades.
• Dull cutting edge.
• Select a grade with a smooth coating.
• Use an insert with a larger rake angle.
• Reduce amount of honing.
• Cutting speed is too slow.
• Increase cutting speeds.
• Feed rate is too slow.
• Increase feed rates.
• Grade lacks thermal resistance.
• Select a more crater-wear-resistant grade.
• Use an insert with a larger rake angle.
• Cutting speed is too fast.
• Decrease the cutting speed
• Feed rate is too fast.
• Reduce feed rates and depth of cut.
• Depth of cut is too large.
• Supply sufficient amount of coolant.
• Not enough cutting fluid.
• Grade lacks wear resistance.
• Select a wear-resistant grade. P30 → P20 → P10 K20 → K10 → K01
• Rake angle is too small.
• Use an insert with a larger rake angle.
• Cutting speed is too fast.
• Alter depth of cut to shift the notch location.