INSERT WEAR SECO TECHNICAL EDUCATION PROGRAM

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FAILURE MODES
1. NORMAL FLANK WEAR 2. CRATERING
Normal Flank Wear, since it is CAUSE
predictable and consistent, is the A combination of diffusion,
most desirable wear condition. decomposition and abrasive wear causes
Rapid flank wear looks the same, cratering. The heat from workpiece
but happens much quicker than the chips promotes decomposition of the
target 15 minutes of time in cut. tungsten carbide grains in the cutting
tool, wearing a ‘crater’ on the top of
CAUSE the insert. The crater will eventually grow large enough to cause the insert
Abrasive wear. Hard microscopic particles or work-hardened material in the flank to chip or deform.
workpiece cut into the insert, wearing away the cutting edge.
WHAT TO LOOK FOR
WHAT TO LOOK FOR QQ Craters or pits on top of inserts
QQ Relatively uniform abrasion along the cutting edge QQ Chipbreaking may improve after cratering starts
QQ Occasionally, metal from the workpiece that is smeared over the
cutting edge can exaggerate the apparent size of the wear scar WHEN TO EXPECT IT
QQ When machining iron (especially steel) or titanium-based alloys
WHEN TO EXPECT IT
In all materials, an insert will fail due to normal wear if it doesn’t fail from CORRECTIVE ACTIONS (TO RAPID FLANK WEAR)
something else first. QQ Use a coated grade
– Coatings containing relatively thick layers of aluminum oxide are best
CORRECTIVE ACTIONS (TO RAPID FLANK WEAR) – TiAlN is the most crater resistant PVD coating
QQ Select a harder, more wear resistant grade. QQ Apply coolant
QQ Apply coolant correctly QQ Use a freer cutting geometry to reduce heat
QQ Reduce the cutting speed (RPM or SFPM) QQ Reduce the cutting speed (RPM or SFPM)
QQ Reduce feed rate
QQ Increasing the lead angle will have a small, but positive, effect

3. BUILT UP EDGE 4. CHIPPING

CAUSE CAUSE
Material adhesion. BUE is a result Mechanical instability. Chipping of
of the workpiece material being the insert edge is often a result
pressure welded to the cutting edge. of vibrations in the workpiece or
This occurs when there is chemical f = V/(5 x WL)
f = vibration frequency (cycles per second)
spindle. Hard inclusions in the
affinity, high pressure, and sufficient V = cutting speed (feet per minute)
WL = wave length of vibration (inches)
surface of the material being cut and
temperature in the cutting zone. interrupted cuts result in local stress
Eventually, the built up edge breaks off and often takes a piece of the concentrations that can cause chipping.
cutting edge with it, leading to chippage and rapid flank wear.
WHAT TO LOOK FOR
WHAT TO LOOK FOR QQ Chips along the edge of the insert
QQ Shiny material on the top or flank of the insert edge
QQ Erratic changes in part size or finish WHEN TO EXPECT IT
QQ Non-rigid set-ups (bad bearings, worn spindles, etc.)
WHEN TO EXPECT IT QQ Interrupted cuts
QQ When machining gummy materials QQ Deflection in the tool or tool holder. Often seen in long drills or long
QQ At low speeds boring bars
QQ When machining high temp alloys and stainless steel QQ Hard spots in work material
QQ Threading operations QQ Powdered Metal (PM) materials
QQ Drilling
QQ When machining non-ferrous materials CORRECTIVE ACTIONS
QQ Ensure proper (rigid) machine tool setup
CORRECTIVE ACTIONS QQ Minimize deflection
QQ Increase the cutting speed (RPM or SFPM) QQ Select a stronger cutting edge geometry
QQ Any coating, but especially a nitride coating, will reduce built-up edge QQ Select a tougher insert grade
QQ Select an insert with a sharper, freer cutting edge geometry QQ Reduce the feed rate (especially at the entrance or exit of the cut)
QQ Apply coolant correctly. Increasing the concentration usually helps QQ See also corrective actions for built-up edge as built-up edge is a
QQ Use an insert with a smoother (polished) surface frequent cause of chipping

TEC-TEAM: 1-800-832-8326
5. THERMAL MECHANICAL FAILURE 6. EDGE DEFORMATION
CAUSE CAUSE
A combination of thermal cycling Excessive heat. Excessive heat causes
(changing the temperature of the the carbide binder (cobalt) to soften.
insert very rapidly), thermal load Mechanical Overloading. Pressure
(temperature differences between of the insert against the workpiece
warm and cold zones), and mechanical makes the insert deform or sag at the
shock causes thermal mechanical tip, eventually breaking off or
failure. Stress cracks form along the insert edge, eventually causing leading to rapid flank wear.
sections of carbide to pull out and appear to be chipping. This is the most
common failure mode encountered in milling applications. WHAT TO LOOK FOR
QQ Deformation at the cutting edge
WHAT TO LOOK FOR QQ The dimensions of the workpiece may not be as expected
QQ Multiple cracks perpendicular to cutting edge
QQ Need to identify before chipping occurs WHEN TO EXPECT IT
QQ High heat operations
WHEN TO EXPECT IT QQ High speed
QQ Milling QQ Hard steels or work-hardened surfaces
QQ Facing operations when a large number of parts are machined QQ High temperature alloys
QQ Operations with intermittent coolant flow QQ High feed rates

CORRECTIVE ACTIONS CORRECTIVE ACTIONS

QQ Apply coolant correctly or remove completely QQ Apply coolant correctly
QQ Select a tougher insert grade (higher cobalt content) QQ Use a harder, more wear resistant grade with a lower binder (cobalt)
QQ Reduce the cutting speed (RPM or SFPM) content
QQ Reduce the feed rate QQ Using a freer cutting insert geometry will have a small but positive effect
QQ Reduce the cutting speed (RPM or SFPM)
QQ Reduce the feed rate
QQ Select an insert with a larger nose radius

7. NOTCHING 8. MECHANICAL FRACTURE

CAUSE CAUSE
Hard or abrasive surfaces on the Mechanical overload. The mechanical
workpiece. Notching is caused when load is so great that the insert breaks,
the surface of the workpiece is often during the first moments of a
harder or more abrasive than the cut. Excessive wear of any type can
material deeper in the cut, e.g. cause mechanical fracture.
surface hardening from previous
cuts, forged or cast surfaces, or surface scale. This causes the insert to wear
more rapidly at the depth of cut line. Local Stress Concentration can also lead WHAT TO LOOK FOR
to notching. As a result of the compressive stress along the cutting edge QQ Fracture of insert. Large segments of the insert gone.
– and lack of the same behind the cutting edge – the insert is particularly
stressed at the depth of cut line. WHEN TO EXPECT IT
QQ Any operation, but especially those involving severe impact such as
WHAT TO LOOK FOR an interrupted cut
QQ Notching or chipping at the depth of cut area on the insert
CORRECTIVE ACTIONS
WHEN TO EXPECT IT QQ Correct for all other failure mechanisms besides normal flank wear
QQ Machining materials with surface scale or oxidation QQ Verify set-up rigidity
QQ Machining work hardened materials QQ Select a tougher insert grade (higher content of cobalt)
QQ Machining cast or irregular surfaces QQ Select a thicker insert
QQ (see also Built Up Edge) QQ Select an insert with a tougher cutting edge
QQ Select an insert with a chipbreaker geometry designed for higher
CORRECTIVE ACTIONS feed rates
QQ Vary the depth of cut when using multiple passes QQ Reduce the depth of cut
QQ Use taper machining techniques when possible QQ Reduce the feed rate
QQ Use a tool with a larger lead angle QQ Check the workpiece for hard inclusions or difficult entry
QQ Increase cutting speed if machining a high temp alloy
– NOTE: This will generate more flank wear
QQ Use a chipbreaker designed for high feed rates
QQ Carefully increase the hone in the DOC area
QQ Select a tougher insert grade
QQ Reduce the feed rate

TEC-TEAM: 1-800-832-8326
GT13-5xx P-1303-2000 Copyright © 2013 Seco Tools, Inc. Printed in USA. All rights reserved.