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What are the causes of blade wear in cutting? How to deal with it?

2020-11-17 14:52:07

Flank wear

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


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



Excessive cutting speed

Insufficient wear resistance

Feeding too low



Reduce cutting speed (VC)

Choose materials with higher wear resistance

Raise the feed (fz)


2. Excessive wear leads to short tool life


 Excessive wear leads to short tool life




Chip recutting

Burrs form on parts

Surface poor quality

generate heat



Raise feed (FZ)

Adopt suitable milling

Use compressed air for effective chip removal

Check the recommended cutting parameters


3. Uneven wear causes damage to sharp corners


Uneven wear causes damage to sharp corners



Tool run out


Short tool life

Surface poor quality

loud noise



Reduce the runout amount to less than 0.02mm

Check collet and collet

Minimize tool overhang

Use fewer teeth for cutting

Choose a larger tool diameter

For solid carbide end mills and replaceable head mills, select groove types with larger helical Angle (GP ≥45°)

Divide axial depth (AP) into multiple cutting knives

Reduced feed (FZ)

Improve tool and workpiece clamping


Crater wear

Excessive wear results in reduced cutting edge strength. A broken cutting edge results in poor surface quality

Crater wear



The cutting temperature of the front blade surface is too high, which leads to diffusion wear



Choose the alumina coating material

Choose the groove shape of front Angle blade

Lower the speed to get a lower temperature, and then lower the feed



The part of the cutting edge that is not involved in the cutting is damaged by a chip hammer. The front and support surfaces of the blade are damaged, resulting in poor surface texture and excessive wear of the rear blade surface





The chip is compressed under the action of the cutting edge



Choose a brand with higher toughness

Choose a blade with a stronger cutting edge

Improve cutting speed VC

Select the front Angle groove

Reduce feed at the beginning of cutting

Improve Dimensional Stability


Groove wear

Trench wear results in poor surface quality and cutting edge fracture risk


 Groove wear



Work hardening material

Epidermis and oxide skin



Reduced cutting speed (VC)

Choose a brand with higher toughness

Use a stronger groove

Use a cutting Angle closer to 45°

Use a round blade to ensure best results

Delay wear using variable AP technology


Built-up edge

The filamentous tumor results in poor surface quality and breaks the cutting edge when detached


 Built-up edge



The cutting area is too cold

Materials such as mild carbon steel, stainless steel, and aluminum are highly viscous



Increase cutting speed

Switch to a more suitable blade groove


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