The Common Wear Problems of CNC Carbide Inserts and Its Solution
1) Flank Wear
Causes for the problem
a)Substrate material is too soft
b)The cutting speed is too high
c)Clearance angle is too small
d)Feeding rate is too low
Solution for the problem
a)Decreasing cutting speed
b)Finding a suitable cutting tip height
c)Selecting the proper proportion between feeding rate and cutting depth
2) Crater Wear
Causes for the problem
a)The substrate material is too soft
b)Cutting speed is too high
c)Feeding is too big
Solution for the problem
a)Decreasing cutting speed or feeding
b)Selection a good grade of tungsten carbide with better wear-resistance performance
c)Selection the cutting tools with positive rake angle
3) Welding
Causes for the problem
a)The cutting speed is too low
b)Cutting edge is not sharp
C)The material of cutting tool and workpiece is not matched
Solution for the problem
a)Adjust the cutting speed
b)Using coolant
c)Reducing chamfer
d)Enlarging rake angle
e)Taking low-effinity material of cutting tool’s
4) Notching
Causes for the problem
a)Mailnly because the cutting speed is too high and the workpiece is too hard ,especially the surface hardness leading to serious friction
b)Serrated chip friction
Solution for the problem
a)Reduce cutting speed
b)Decrease primary angle
c)Selection tungsten carbide grade with better wear-resistance performance
5)Thermal Cracking
Causes for the problem
a)The cracks would be emerged in the cutting edge due to temperature change in intermittent cutting process .
b)The material of cutting tools is too hard
Solution for the problem
a)Selecting a material with better heat-resistance performance
b)Using coolant enough and continuely
6)Flaking
Causes for the problem
a)The resistance force of chips is too high
b)The cutting depth or feeding is too big
c)Chips falls off
d)Poor chip breaker
Solution for the problem
a)Selection harder tungsten carbide material
b)Taking comparatively stable cutting edge geometry shape to avoid chip shocks
c)To change the direction of chip-removal by changing the cutting value of chip-breaker
