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    Drilling Inserts Wear Problems and Solutions

    SOLID CARBIDE
    DRILLING - INDEXABLE HEAD
    DRILLING - INDEXABLE INSERTS

    Type of Wear
      • ×
        Flank Wear
        Flank Wear
        Cause
        • High cutting speed
        • Low wear resistance carbide grade

        Remedy
        • Check that the correct geometry is used
        • Increase coolant pressure
        • Change to harder grade
        • Increase oil concentration percentage
        • Reduce cutting speed.*** increase feed
      • ×
        Crater Wear
        Crater Wear
        Cause
        • Excessive cutting temperatures and pressures on the top of the insert

        Remedy
        • Reduce cutting feed
        • Check that the correct geometry is used
      • ×
        Plastic Deformation
        Plastic Deformation
        Cause
        • Cutting temperature is too high

        Remedy
        • Check cutting parameters
        • Reduce cutting feed
        • Increase coolant pressure/volume
        • Use harder grade
        • Check that the correct geometry is used
      • ×
        Thermal Cracking
        Thermal Cracking
        Cause
        • Excessive variations in surface temperature, intermittent machining, or variations in coolant supply

        Remedy
        • Increase coolant pressure/volume
        • Increase oll concentration percentage
      • ×
        Corner Fracture
        Corner Fracture
        Cause
        • Caused by excessive insert wear before indexing the insert
        • The grade and geometry could be too weak for the applications
        • Excessive load on the insert
        • Built-up edge has been formed on the insert

        Remedy
        • Check radial runout
        • Reduce feed rate increase the speed
        • Check tool and part clamping rigidity
        • Check if pocket gripping force is too low, replace the holder
        • Increase coolant pressure
        • Improve jet direction in case of external coolant supply
      • ×
        Built-up Edge
        Built-up Edge
        Cause
        • Cutting zone temperature is too low
        • Negative cutting geometry
        • Machining of very sticky materials such as low-carbon steel, stainless steels, and aluminum

        Remedy
        • Increase the feed
        • Increase cutting speed
        • Increase coolant pressure
        • Check oil percentage in the coolant fluid
      • ×
        Edge Chipping
        Edge Chipping
        Cause
        • Low wear resistance carbide grade
        • Built-up edge has been formed
        • Insufficient cutting fluid

        Remedy
        • Reduce feed rate
        • Increase cutting speed
        • Increase coolant pressure
        • Improve jet direction in case of external coolant supply
        • Change to different geometry
        • Check tool and part clamping rigidity
      • ×
        Chisel Chipping
        Chisel Chipping
        Cause
        • Chisel runout is too big
        • Combine high feed & low speed

        Remedy
        • Reduce feed rate and increase the cutting speed
        • Check that chisel misalignment does not exceed 0.02mm
        • Check tool and part clamping rigidity
        • Check if pocket gripping force is too low, replace the holder
      • ×
        Corner Chipping
        Corner Chipping
        Cause
        • Radial runout is too big
        • Insufficient cutting fluid

        Remedy
        • Check radial runout
        • Reduce feed rate increase the speed
        • Check tool and part clamping rigidity
        • Check if pocket gripping force is too low, replace the holder
        • Increase coolant pressure
        • Improve jet direction in case of external coolant supply
      • ×
        Land Wear
        Land Wear
        Cause
        • Cutting speed too high
        • Low wear resistance carbide grade
        • Radial runout is too big

        Remedy
        • Check that the correct geometry is used
        • Check that T.I.R runout does not exceed 0.02mm
        • Reduce cutting speed
        • Increase coolant pressure
        • Improve jet direction in case of external coolant supply
        • Check and improve tool and part clamping rigidity
        • Check if pocket gripping force is too low, replace the tool body
      • ×
        Flank Wear
        Flank Wear
        Cause
        • High cutting speed
        • Low wear resistance carbide grade

        Remedy
        • Check that the correct geometry is used
        • Increase coolant pressure
        • Change to harder grade
        • Increase oil concentration percentage
        • Reduce cutting speed.*** increase feed
      • ×
        Crater Wear
        Crater Wear
        Cause
        • Excessive cutting temperatures and pressures on the top of the insert.

        Remedy

        • Reduce cutting feed
        • Check that the correct geometry is used
      • ×
        Plastic Deformation
        Plastic Deformation
        Cause
        • Cutting temperature is too high

        Remedy
        • Check cutting parameters
        • Reduce cutting feed
        • Increase coolant pressure/volume
        • Use harder grade
        • Check that the correct geometry is used
      • ×
        Thermal Cracking
        Thermal Cracking
        Cause
        • Excessive variations in surface temperature, intermittent machining, or variations in coolant supply

        Remedy
        • Increase coolant pressure/volume
        • Increase oll concentration percentage
      • ×
        Corner Fracture
        Corner Fracture
        Cause
        • Caused by excessive insert wear before indexing the insert
        • The grade and geometry could be too weak for the applications
        • Excessive load on the insert
        • Built-up edge has been formed on the insert

        Remedy
        • Check radial runout
        • Reduce feed rate increase the speed
        • Check tool and part clamping rigidity
        • Check if pocket gripping force is too low, replace the holder
        • Increase coolant pressure
        • Improve jet direction in case of external coolant supply
      • ×
        Built-up Edge
        Built-up Edge
        Cause
        • Cutting zone temperature is too low
        • Negative cutting geometry
        • Machining of very sticky materials such as low-carbon steel, stainless steels, and aluminum

        Remedy
        • Increase the feed
        • Increase cutting speed
        • Increase coolant pressure
        • Check oil percentage in the coolant fluid
      • ×
        Edge chipping
        Edge chipping
        Cause
        • Low wear resistance carbide grade
        • Built-up edge has been formed
        • Insufficient cutting fluid

        Remedy
        • Reduce feed rate
        • Increase the speed
        • Increase coolant pressure
        • Improve jet direction in case of external coolant supply
        • Change to different geometry
        • Check tool and part clamping rigidity
      • ×
        Chisel Chipping
        Chisel Chipping
        Cause
        • Chisel runout is too big
        • Combine high feed & low speed

        Remedy
        • Reduce feed rate and increase the cutting speed
        • Check that chisel misalignment does not exceed 0.02mm
        • Check tool and part clamping rigidity
        • Check if pocket gripping force is too low, replace the holder
      • ×
        Land Wear
        Land Wear
        Cause
        • Cutting speed too high
        • Low wear resistance carbide grade
        • Radial runout is too big

        Remedy
        • Check that the correct geometry is used
        • Check that T.I.R runout does not exceed 0.02mm
        • Reduce cutting speed
        • Increase coolant pressure
        • Improve jet direction in case of external coolant supply
        • Check and improve tool and part clamping rigidity
        • Check if pocket gripping force is too low, replace the tool body
      • ×
        Corner Chipping
        Corner Chipping
        Cause
        • Radial runout is too big
        • Insufficient cutting fluid

        Remedy
        • Check radial runout
        • Reduce feed rate increase the speed
        • Check tool and part clamping rigidity
        • Check if pocket gripping force is too low, replace the holder
        • Increase coolant pressure
        • Improve jet direction in case of external coolant supply
      • ×
        Flank Wear
        Flank Wear
        Cause
        • High cutting speed
        • Low wear resistance carbide grade

        Remedy
        • Reduce cutting speed
        • Increase coolant pressure/volume
        • Choose better wear resistance grade
        • Increase oil concentration percentage
      • ×
        Crater Wear
        Crater Wear
        Cause
        • Excessive cutting temperatures and pressures on the top of the insert

        Remedy
        outer insert:
        • Reduce cutting speed
        • Choose better wear resistance grade
        • Change to different chipbreaker

        inner insert:
        • Reduce feed rate
        • Change to different chipbreaker
      • ×
        Plastic Deformation
        Plastic Deformation
        Cause
        • Cutting temperature is too high

        Remedy
        • Reduce feed rate
        • Choose better wear resistance grade
        • Increase coolant pressure/volume
        • Choose a different chipbreaker
      • ×
        Thermal Cracking
        Thermal Cracking
        Cause
        • Excessive variations in surface temperature, intermittent machining, or variations in coolant supply

        Remedy
        • Use tougher grade
        • Increase coolant pressure/volume
      • ×
        Edge Fracture
        Edge Fracture
        Cause
        • Caused by excessive insert wear before indexing the insert
        • The grade and geometry could be too weak for the applications
        • Excessive load on the insert
        • Built-up edge has been formed on the insert

        Remedy
        • Use tougher grade
        • Reduce feed rate
        • Increase coolant pressure/volume
        • Change to different chipbreaker
      • ×
        Built-up Edge
        Built-up Edge
        Cause
        • Cutting zone temperature is too low
        • Negative cutting geometry
        • Machining of very sticky materials such as low-carbon steel, stainless steels, and aluminum

        Remedy
        • Increase cutting speed
        • Change to different chipbreaker
        • Reduce feed rate
        • Increase coolant pressure/volume
      • ×
        Chipping
        Chipping
        Cause
        • Low wear resistance carbide grade
        • Built-up edge has been formed
        • Insufficient cutting fluid

        Remedy
        • Choose tougher grade
        • Reduce feed
        • Increase coolant pressure/volume
        • Change to different chipbreaker

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