Troubleshooting for Cutting Tools

There is one simple fact about carbide cutting tools — they eventually fail during use, no matter
how high their quality. The extreme cutting forces and high temperatures generated by a
machining operation take a tremendous toll on the cutting tool.

The key is to recognize the type of failure so preventive measures can be taken to maximize
productivity and minimize tooling costs. Oftentimes, more than one type of failure is the culprit,
making it difficult to accurately diagnosis the cause of the failure. Therefore, a good
understanding of the different types of cutting tool failure is essential. An incorrect diagnosis may
lead to control actions that worsen the problem instead of improve it.
The eight most common types of cutting tool failure are discussed below. They are abrasive flank
wear, cratering, built-up edge, chipping, thermal cracking, plastic deformation, notching, and
fracture.

Abrasive Flank Wear

Of all cutting tool failures, abrasive flank wear is the most desirable and predictable, because it
means the insert simply wore out over a period of time. Abrasive flank wear is caused by the
abrading action of the workpiece against the cutting edge of the insert. Although this abrasive
action is a normal part of the machining process, it causes a "wear land" to appear on the flank of
the cutting tool, as shown in the figure above. The degree to which a wear land develops is
directly related to the time of the cut. As shown in the chart below, there are basically three
"zones" of wear land development.

Zone "A" is referred to as the "break-in" period and is characterized by rapid flank wear. Zone "B"
makes up the largest part of the cutting tool's life. In this zone, wear is constant and very
predictable. In Zone "C," the cutting forces and high temperatures begin to exceed what the
cutting tool can withstand. These extreme conditions accelerate flank wear and ultimately cause
the cutting tool to fail. Therefore, cutting tools should be indexed at the beginning of Zone "C,"
before unpredictable flank wear causes problems with the finish of the workpiece.
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Cratering

The type of failure known as "cratering" is characterized by a concave wear pattern on the rake
surface of an insert, as shown in the figure. This wear pattern occurs when small particles of the
cutting tool are worn away by the chip as it passes over the rake surface. If not corrected, this
erosion process will continue until the crater breaks through to the cutting edge causing complete
failure of the insert. Although elimination of the crater is not always possible, the growth of the
crater can often be controlled so that normal flank wear preempts a failure caused by the crater.

Suggested Control Actions

Use TiC or Al 2O3 coated grades. These types of grades have high hardness values and
exhibit excellent crater wear resistance.
Use TiC-bearing grades. Uncoated grades that have TiC in their composition also exhibit the
same crater wear resistance as coated grades containing TiC or Al 2O3.
Use coolant. If coolant is not being used but is an option, it can sometimes help in the control
of crater failure. The lubricating and heat-reducing effect of the coolant may suppress the
conditions necessary for crater formation.
Reduce operating conditions. If the above suggestions do not control the cratering problem,
the operating conditions may need to be reduced. This will result in lower productivity and is the
least desirable of the suggested control actions, but reducing the operating conditions may be the
best solution to the cratering problem.

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Built-Up Edge

The failure mode known as "built-up edge" occurs when the extreme forces at the point of contact
between the cutting tool and the workpiece weld small particles of the workpiece to the cutting
tool, as illustrated in the figure. This type of failure is common when machining a soft, malleable
workpiece at slower than recommended cutting speeds. The built-up edge reduces the efficiency
of the cutting tool, which increases the cutting forces on the insert and often leads to chipping of
the cutting tool.

Suggested Control Actions

Increase feed rate. If the conditions that cause the built-up edge condition can be reduced, the
built-up edge can be controlled or eliminated. Increasing the feed rate (surface feet per minute)
reduces the cutting time and, consequently, reduces the opportunity for any welding action to
form a built-up edge. This solution may also increase productivity and improve the surface finish
of the workpiece.
Use coolant. Many types of coolant interfere with any welding action by "contaminating" the
surfaces of the workpiece and the cutting tool. Since welding requires a clean surface, the
residue of the used coolant on the workpiece and the cutting tool helps prevent the formation of a
weld.
Remove coolant. If coolant is being used in the operation, it may be cooling the cutting edge to
a temperature suitable for the welding action can take place. Removing the coolant will increase
the temperature of the cutting edge, reducing the likelihood that workpiece materials can weld to
the cutting edge.
Use an insert with a positive rake angle. Cutting tools with positive rake angles help reduce
the cutting forces necessary for the built-up edge to form.
Use TiC or Al2O3 coated grades. These types of grades have anti-welding characteristics and
higher hardness values that help to impede the formation of a built-up edge.

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Chipping

The failure mechanism called "chipping" occurs when small pieces of the carbide insert are
chipped away from the cutting edge during the machining process, as shown in the figure.
Eventually, increased cutting forces at the chipped cutting edge cause the cutting edge to
become inefficient, leading quickly to catastrophic failure. Chipping may not always be obvious.
Some chipping occurs microscopically, the appearance of which may be confused with normal
flank wear unless examined closely. Chipping can result from a variety of conditions poor rigidity
in the tooling set-up, weak cutting edge, deflecting workpiece, inadequate machine tool, varying
cutting loads.

Suggested Control Actions

Minimize deflections. Deflection can originate in the tooling set-up, the workpiece, chucking or
fixturing of the machine tool, or in the tool blocks, tail stock, live centers, carriages, cross slides,
and rests. Any such deflection causes varying cutting loads on the insert that can lead to
chipping. To minimize deflections, check the machine tool for excessive clearance in the spindle
bearings and the gibs, check the toolholder or boring bar for excessive overhang and secure
clamping, and use large boring bars with low length-to-diameter ratios.
Increase edge preparation on inserts. The cutting edge of an insert is honed to increase its
strength. Honing helps evenly distribute the cutting forces along the cutting edge, thereby making
it stronger. The amount of hone required depends on the cutting forces to be encountered during
the machining process. Greater shock loads require heavier hones. Although most cutting tools
are purchased with honed cutting edges, a heavier hone or a "T"-land may be required in extreme
applications.
Use an insert with a stronger geometry. Negative rake inserts are stronger than positive rake
inserts and are capable of handling greater shock loads. If negative rake inserts aren't available,
use positive rake inserts with smaller relief angles. Also, inserts with large nose radii are stronger
than inserts with small nose radii.
Use a tougher carbide grade. If deflections have been minimized and cutting edges have been
honed and chipping still occurs, it may be necessary to change to a more shock-resistant carbide
grade with a higher cobalt content. However, the feed rate will probably have to be reduced to
avoid other types of failure, which will decrease productivity. This solution should be the last
alternative chosen.
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Thermal/Mechanical Failure

Thermal/mechanical failure appears on the cutting tool as cracks that are generally perpendicular
to the cutting edge, as seen in the figure. This type of failure is usually caused by the inability of
the cutting tool to withstand the extreme temperature variations of interrupted cutting operations.
The heat produced in such machining operations tends to remain at the cutting edge instead of
being transferred to the rest of the insert, because carbide is a poor conductor of heat. This
causes extreme thermal stress on the overheated cutting edge causing it to crack.

Suggested Control Actions

Use coolant correctly or don't use it at all. If coolant is applied intermittently or in insufficient
volume, the thermal cracking problem will be worsened. If coolants cannot be applied correctly,
the operation should be performed without coolant at reduced speed, feed, and depth of cut.
Use a stronger carbide grade. Stronger grades of carbide with higher cobalt content have
greater tolerance to extreme temperature changes. Grades with TaC also possess heat-resistant
characteristics.

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Plastic Deformation

The type of failure known as "plastic deformation" occurs when the carbide at the cutting edge is
softened by the high temperatures produced during machining operations. The softened carbide
is deformed from its original shape by the cutting forces, as shown in the figure. When a cutting
edge appears to have developed a large wear land after a very short time, plastic deformation
should be suspected.

Suggested Control Actions

Use coolant. The use of coolant to reduce the temperature of the insert at the cutting edge will
prevent plastic deformation by allowing the cutting tool to maintain its hardness and better
withstand the cutting forces.
Reduce operating conditions. The reduction in feed, speed, or depth of cut will reduce the heat
and cutting forces generated at the cutting edge. This will result in lower productivity and is the
least desirable of the suggested control actions, but reducing the operating conditions will correct
the problem.
Use a more wear-resistant grade. Carbide grades that are wear-resistant also resist plastic
deformation. These grades generally have lower cobalt content and higher hardness values and
may contain TiC or TaC.

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Notching

The failure mechanism called "notching" appears as a severe "notch-shaped" abrasive wear
pattern that is localized at the depth-of-cut line, as illustrated in the figure. Notching generally
occurs during the machining of high temperature alloys and work-hardened materials, where
"scale" material on the surface of the workpiece is very hard and causes accelerated abrasive
wear on the insert at the depth-of-cut line.

Suggested Control Actions

Use tooling that provides a large cutting edge angle to the workpiece. The large cutting edge
angle distributes the cut over a larger section of the insert, which weakens the chip and reduces
the abrasive effect on the insert's cutting edge.
Increase the hone at the depth-of-cut line area of the cutting edge. A stronger edge at the
depth-of-cut line achieved by additional honing will improve the insert's resistance to the abrasive
action of the scale on the workpiece.
Reduce the feed rate. If the application of a larger cutting edge angle does not solve the
problem, a reduction in feed rate may be necessary to eliminate notching. However, this will
decrease productivity and should only be used if other attempted solutions fail.

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Fracturing

"Fracturing" occurs when the cutting forces exceed the strength of the insert's cutting edge
causing catastrophic removal of a large piece of the cutting tool, as shown in the figure. Several
circumstances can cause fracturing, including excessive flank wear land, shock loading during
interrupted cutting operations, improper carbide grade selection, and improper insert size
selection. Fracturing may result in injury to the operator, the inability to use the remaining unused
cutting edges of the insert, and damage to the workpiece, toolholder, or machine tool.

Suggested Control Actions

Index the insert before the wear land reaches its end-point. Fracturing will occur when the
wear land reaches its end-point, or the point at which it can wear no more. Therefore, the insert
should be indexed before this occurs.
Use a tougher carbide grade. Carbide grades with higher cobalt content are generally tougher
and more resistant to the shock loads that can cause fracturing.
 Use an insert of appropriate size. If fracturing occurs, the insert is not able to withstand the
cutting forces of the machining operation. A larger or thicker insert will absorb more shock forces.
Use an insert with a stronger geometry. Negative rake inserts are stronger than positive rake
inserts and are capable of handling greater shock loads. Also, inserts with large nose radii are
stronger than inserts with small nose radii.
Use honed inserts. The cutting edge of an insert is honed to increase its strength. Honing
helps evenly distribute the cutting forces along the cutting edge, thereby making it stronger. The
amount of hone required depends on the cutting forces to be encountered during the machining
process. Greater shock loads require heavier hones. Although most cutting tools are purchased
with honed cutting edges, a heavier hone may be required in extreme applications.
Reduce operating conditions. The reduction in feed, speed, or depth of cut will reduce the
cutting forces generated at the cutting edge. This will result in lower productivity and is the least
desirable of the suggested control actions, but reducing the operating conditions may be the only
solution..
Use a toolholder with better support. If an insert does not have sufficient support in the
toolholder, it may fracture. A toolholder with proper support must be used or even the best
inserts will fracture.

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