CUTTING TOOLS

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 Main stage of cutting process with tools

First step
Tool penetrates rock surface and generates a contact zone for
stress transfer.
A stress zone around the tools tip is generated

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 Main stage of cutting process with tools

Second step
Conteporary generation of a crushed zone ahead of the tools tip
and enlarging of stress zone

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 Main stage of cutting process with tools

Third step
After exceeding a critical stress rupture of chip element and
consecutive immediate stress release

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 Tool spacing

Close spacing, overcrushingh

Not optimum, can create small chip size or dust. Also premature
tool wear.

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 Tool spacing

This is what you do not want to see.

The spoil pile is 100% fines. The teeth are not penetrating the rock.

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 Tool spacing

Large spacing, no cut interaction per pass, chipping is not very

effective or no chip forming
Can cause increased wear on tools and holders.
Characterized by ridges between tool marks in trench

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 Tool spacing

Optimum spacing, maximum distance with interaction between the

cuts, efficent chipping
Maximum tool performance

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 Tool spacing

You want to see good sized chips in the spoil pile.

These teeth are penetrating to produce chips.

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 Conical tooth

Hardfacing
Tip

Gage
Length
Braze Body
Cavity

Collar

Shank

Retainer
Groove

Hub

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 Tip styles

Advantage : Our competitors place less carbide in

their plug tips. So when a competitor claims they are
comparing apples to apples, they are misleading the
customer.

Plug: Maximum toughness. Physical lock between

steel and carbide.

Conditions: Good in hard rock, chunk rock, shot

rock, mixed rock and dirt. Areas were there is
excessive impact.

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 Tip styles

Advantage: This is the premier tip in abrasive

applications. The carbide is on the business end, not
sunk into the shank.

Cap: Maximum abrasion resistance. Rely on braze joint

strength to hold tip to steel body. Will not withstand high
impact as well as plug.

Conditions: Penetration, Good in softer more abrasive

material. Helps divert material away from steel body,
reducing steel wash. Areas with uninterrupted cuts.

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 Tip styles

Advantage: This tip provides the ability to withstand

abrasive material like a cap, along with the plug
support for stability. The NB tool does not get blunt
like a Cap at the end of wear life .

NB: Combines desirable features of a cap and a plug,

with good toughness and good abrasion resistance.

Conditions: Excels in hard, abrasive material.

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 Balanced carbide/steel wear

Plug tip in soft, abrasive Cap tip in same

material. conditions

Balanced wear
Exposed
carbide

Result: Steel wash & Result: Increased tooth life

premature tip loss and increased production.
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 Failure guide

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 Failure guide

C1. Carbide crushed

Overload on the tool tips when cutting harder rock formations.This starts usually with a
chip ( C2 damage ) and then the
tip fractures. Tip is too small for cutting
conditions
Change to larger diameter carbide, look at drum/head lacing, go to tighter spacing with
more tool positions, which results in lower load per tool.

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 Failure guide

C2. Carbide chipped

Tip point overloaded. This results later in a C1 damage, crushed carbide, see
above.
Change: Check if carbide quality is OK.

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 Failure guide

C5. Thermal fatigue cracks leading to chipping

Capped tools cutting without cooling (dry) like gypsum and salt must have sharp tips.
When tip is getting blunt, friction forces increases and the temperature variations
increase. Thermal cracks grow deep and tips start chipping.
Change to new tools and if possible lower cutting speed. Use sharpest possible slim
tools with very wear resistant grade.

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 Failure guide

S4. Steel wash

Steel body wears much faster than carbide. Occurs in softer formations when carbide last
long. Here the carbide tip shows abrasive wear.
Change: to capped tools less wear resistant std grades. Change when cylindrical part of
carbide sticks out more than 10 mm from steel. Check tool lacing, attack and skew angles.

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 Failure guide

S3. Steel around carbide cracked and chunked away

The carbide insert is lost, and this could have started with a S1 damage.
Change:See under S1 and check braze and steel quality.
Bad braze contact can also make inserts to move in the pocket under load.
The steel will then be plastified, and the tip is pushed out and lost.

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 Failure guide

B1. Total braze failure. No or little carbide left

No braze wetting around the periphery. Check brazing quality. If heating of tip base makes
the braze melt, then change to tools with slim inserts and sharp tips.

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 Failure guide

W1. Worn out tool. Good rotation.

Tool was changed to late, which have damaged sleeves and tool holders.

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 Failure guide

U1. Damaged tool.Beyond recognition.

No info. Check more tools from same job to get info regarding what has caused the tool
failures.

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 Failure guide

R1. Wear flat due to stopped tool rotation

Can depend on many things.Wrong lacing (incorrect tool angles), to little play between tool
and sleeve, clogged sleeves, interruptions in cooling or not having cleaning heads/drums
before long stillstands.
Check if sleeves or blocks are clogged and control spray nozzles if water cooling is used.

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 Recommendation

1. Go to a cap tip to prevent premature steel wash

2. If conditions cause failure of cap go to NB style tip.

3. The harder the rock, the shorter the gage of the head

4. The softer the rock, the longer the gage of the head

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 Best customer value

Optimum machine performance

Complete job FAST

Minimum effort

Minimum down-time

Lowest cost consumables

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