Reasons and countermeasures for wear of carbide inserts

1. Grade, specification selection is not appropriate

Countermeasures: Increase the thickness of the insert or the insert will be mounted, select the bending strength and toughness of the higher grade.

2. Improper selection of tool geometry parameters (such as before and after the angle is too large, etc.).

Countermeasures: Can start from the following aspects to redesign the tool.
① Reduce the front and rear angles appropriately.
② Adopt larger negative edge inclination.
③ Decrease the main offset angle.
④ Adopt larger negative chamfer or edge rounding.
⑤ Sharpen the transition cutting edge and strengthen the tip.

3. Incorrect welding process of the insert, resulting in excessive welding stress or welding cracks.

① Avoid the use of three sides of the closed insert groove structure.
② correct choice of solder.
③ Avoid using oxyacetylene flame heating welding, and after welding should be kept warm to eliminate internal stress.
④ Switch to mechanical clamping structure as far as possible.

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4. Cutting volume selection is unreasonable.

Countermeasures: Re-select the cutting amount. Avoid such as the amount of too large, then the machine tool boring; intermittent cutting, cutting speed is too high, the feed is too large, the blank allowance is not uniform, the depth of cut is too small, cutting high manganese steel and other work hardening tendency of the material, the feed is too small and so on.

5. Mechanical clamping tool groove bottom surface is not flat or the insert extends too long and other structural reasons.

Countermeasures:
① Repair the bottom of the groove.
② Reasonable arrangement of the location of the cutting fluid nozzle.
③ Hardened shank in the insert under the increase in carbide shims.

6. Excessive tool wear.

Countermeasures: Timely replacement of the insert or replacement of the cutting edge.

7. Cutting fluid flow is insufficient or incorrect filling method, resulting in sudden heat and cracking of the insert.

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Countermeasures:
① Increase the flow of cutting fluid.
② Reasonable arrangement of cutting fluid nozzle position.
③ Use effective cooling methods such as spray cooling to improve the cooling effect.
④ Use dry cutting to minimize impact on the insert.

8. Incorrect tool installation.

Countermeasures: Re-installation of the tool. Avoid such as: cut off the tool is installed too high or too low, face milling cutter using asymmetric milling and so on.

9. Process system rigidity is too poor, resulting in excessive cutting vibration.

Countermeasures:
① Increase the auxiliary support of the workpiece to improve the workpiece clamping rigidity.
② Decrease the length of the tool suspension.
③ Reduce the back angle of the tool.
④ Use other anti-vibration measures.

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