Welcome To Our Website. Any questions about PCD cutting, brazing and grinding, Call Us:+86 17700605088

Tool breakage, chipping

2021-08-09 18:51:29

Having been in the machining industry for many years, you must be no stranger to tool failure.Tool failure will affect machining accuracy and productivity, operator safety, and part quality.When tool breakage is observed, the machining process should be carefully analyzed in time to find the root cause.


Flank wear 

Flank wear refers to the abrasion loss of the flank of the tool immediately below the cutting edge. The carbide particles in the workpiece material or the work-hardened material rubs against the blade. Small pieces of the coating peel off and the blade rubs. The cobalt element in the blade is finally separated from the crystal lattice, reducing the adhesion of the cemented carbide and thus peeling off.

pcd grinding

Relatively uniform wear along the cutting edge. Sometimes flaking work material sticks to the cutting edge, making the wear look exaggerated than it actually is. Duratomic blades are black when worn, while the wear of ordinary blades is shiny. The black color is the bottom coating that is displayed after the surface coating is peeled off.

pcd grinding



Flank chipping

Flank chipping refers to a mechanical failure that occurs when small particles on the cutting edge are peeled off instead of being worn away by the flank. Flank face spalling occurs when there is an impact load change, such as intermittent cutting. Flank chipping is often the result of unstable workpiece conditions, such as when the tool is too long or the workpiece is under-supported. The secondary cutting of chips is also easy to cause chipping. Rake face peeling.

Viscous materials will spring back after cutting. This springback may exceed the clearance angle of the tool and create friction between the clearance surface of the tool and the workpiece. This friction will cause a polishing effect and may cause work hardening of the workpiece. It will increase the contact between the tool and the workpiece, which will cause heat to cause thermal expansion, leading to expansion of the rake face, and chipping of the rake face.

Rake area edge  

Certain workpiece materials may create a rake area between the chip and the cutting edge. When the continuous lamination of the workpiece material is connected to the cutting edge, built-up edge will occur. The built-up tumor is a dynamic structure. During the cutting process, the cut surface of the built-up edge continuously peeled off and reattached.

pcd grinding

The cutting edge of the rake area also tends to occur at low processing temperatures and relatively slow cutting speeds. The actual speed at which a cutting edge occurs in the rake area depends on the material being processed. If the work hardening material is processed, such as austenitic stainless steel, then the cutting edge area of ??the rake can cause rapid accumulation at the depth of cut, resulting in a secondary failure mode of damage at the depth of cut.

TAG:  Tool breakage, tool chipping,flank chipping,rake area edge

  • Optimizing PCD tool grinding: the transition from roughing to precision machining
    28 February 2024

    Optimizing PCD tool grinding: the transition from roughing to precision machining

    In response to the needs of end customers for grinding PCD tools, this article proposes an optimized processing plan through the analysis of customer equipment, workpieces and processing parameters. The transformation from rough machining to precision machining aims to improve processing efficiency and workpiece quality.

  • How to grind sapphire workpieces
    27 February 2024

    How to grind sapphire workpieces

    Sapphire consists of Al2O3 and has a Mohs hardness of 9, which is second only to superhard materials in hardness. Due to its superior light transmittance and wear resistance, it is mostly used in the substrate of LED light-emitting components, optical windows, and watch cases of high-end watches and cell phone cameras, etc.The processing process usually requires high precision, fast processing efficiency, low material loss and a clean working environment. Diamond is the hardest and most wear-resistant material in nature, so diamond tools are the best choice for processing sapphire materials.

  Add:  Zhongyuan Rd, Zhongyuan District, Zhengzhou, 450001, Henan, China

  Tel: +86 17700605088

  WhatsApp:+86 17700605088

  E-mail: pcd@moresuperhard.com