What Is The Main Cause of Carbide Tool Wear?

Formed carbide milling cutters are widely used due to their tight form tolerances. Since the inserts cannot be replaced directly, most milling cutters are scrapped after the inserts collapse, which greatly increases the processing cost. Next, ZZBETTER will analyze the reasons for the wear of the carbide cutting edge.

1. Characteristics of processing materials

When cutting titanium alloys, due to the poor thermal conductivity of titanium alloys, chips are easy to bond or form chip nodules near the edge of the tooltip. A high-temperature zone is formed on the front and back sides of the tool face close to the tooltip, causing the tool to lose red and hard and increase wear. In high-temperature continuous cutting, the adhesion and fusion will be affected by subsequent processing. In the process of forced flushing, part of the tool material will be taken away, resulting in tool defects and damage. In addition, when the cutting temperature reaches above 600 °C, a hardened hard layer will be formed on the surface of the part, which has a strong wear effect on the tool. Titanium alloy has low elastic modulus, large elastic deformation, and large rebound of the workpiece surface near the flank, so the contact area between the machined surface and the flank is large, and the wear is serious.

2. Normal wear and tear

In normal production and processing, when the allowance of continuous milling titanium alloy parts reaches 15mm-20mm, serious blade wear will occur. Continuous milling is extremely inefficient, and the workpiece surface finish is poor, which cannot meet production and quality requirements.

3. Improper operation

During the production and processing of titanium alloy castings such as box covers, unreasonable clamping, inappropriate cutting depth, excessive spindle speed, insufficient cooling, and other improper operations will lead to tool collapse, damage, and breakage. In addition to ineffective milling, this defective milling cutter will also cause defects such as concave surface of the machined surface due to "bite" during the milling process, which not only affects the machining quality of the milling surface, but also causes workpiece waste in severe cases.

4. Chemical wear

At a certain temperature, the tool material chemically interacts with some surrounding media, forming a layer of compounds with a lower hardness on the surface of the tool, and the chips or workpieces are wiped off to form wear and chemical wear.

5. Phase change wear

When the cutting temperature reaches or exceeds the phase transition temperature of the tool material, the microstructure of the tool material will change, the hardness will decrease significantly, and the resulting tool wear is called phase transition wear.

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