Formed carbide milling cutter is widely used due to small shape tolerance, because of the inability to directly replace the insert, the milling cutter chipped most of the scrap treatment, greatly increasing the processing cost.

Carbide milling cutter in the process of use, edge breakage and wear is a common phenomenon, affecting the machining accuracy and efficiency. There are many reasons leading to carbide milling cutter edge breakage and wear, the following are some of the main reasons and their solutions:

1. Inappropriate cutting parameters

Reason: Inappropriate cutting speed, feed and depth of cut, especially in high-speed cutting, if the cutting parameters are set too high, it will lead to overheating of the milling cutter or excessive cutting force, resulting in edge wear or breakage.

In normal production processing, when continuous milling of titanium alloy parts with a margin of 15mm-20mm there will be serious wear of the cutting edge. The efficiency of continued milling is extremely low, and the surface finish of the machined part is very poor, which cannot meet the production and quality requirements.

Solution:

Reasonably adjust the cutting parameters to avoid excessive cutting speed and feed.

According to different material characteristics and milling cutter use requirements, adjust the appropriate cutting conditions.

Use suitable coolant or cutting fluid to avoid milling cutter edge damage due to high temperature.

2. Excessive cutting force

Cause: Excessive cutting force will cause excessive vibration of the milling cutter, which will accelerate the wear of the cutting edge.

Solution:

Adopt reasonable process path and tool geometry angle to reduce the cutting force.

Choose the right tool material, such as high toughness, high wear resistance carbide tools.

Use highly rigid machine tools and fixtures to avoid tool vibration.

3. Improper use of cutting fluid

Cause: Inadequate or inappropriate role of cutting fluid, resulting in high tool temperature, edge annealing, which in turn accelerates wear.

Solution:

Select the appropriate cutting fluid and ensure that its flow is sufficient to ensure that the tool heat dissipation.

Regularly check the concentration and quality of the cutting fluid to avoid the cutting fluid being too dirty or too thick.

4. Inappropriate tool material

Reason: Improper selection of carbide tool material, such as not choosing the right alloy or coating, leads to insufficient wear resistance of the tool and easy edge wear.

When cutting titanium alloy, due to the poor thermal conductivity of titanium alloy, chips are easily bonded near the tip of the cutting edge or form chip tumors, forming a high temperature zone on the front and back of the cutting surface near the tip of the cutting edge, resulting in the loss of red hardness of the tool and increased wear.

Solution:

Select the appropriate tool material according to the hardness of the workpiece material and processing requirements.

You can choose to have a higher wear resistance and heat resistance coating of cemented carbide tools, such as TiAlN, AlTiN coating.

5. Unreasonable tool geometry angle

Reason: Unreasonable design of the cutting angle, main deflection angle and back angle of the tool may lead to a larger cutting force during the cutting process, which in turn accelerates tool wear.

Solution:

Adjust the tool geometry angle according to the specific machining conditions, e.g. increase the main deflection angle of the cutting edge to reduce the cutting force.

Use suitable tool grinding techniques to maintain the sharpness of the tool edge.

6. Hardness or brittleness of the machining material

Cause: Excessive hardness or brittleness of the workpiece material may cause the tool edge to be susceptible to impact or plastic deformation, thus accelerating wear.

Solution:

Select appropriate cutting conditions according to the characteristics of the material.

Use tools resistant to high hardness or high brittleness materials, such as diamond coated or cemented carbide tools.

7. Machine vibration and tool rigidity is not enough

Reason: Machine vibration or poor tool fixation will lead to severe vibration of the milling cutter during machining, accelerating the wear of the cutting edge, or even breakage.

Solution:

Ensure the stability and rigidity of the machine tool, regularly check the accuracy of the machine tool and the workpiece clamping device.

Use high rigidity toolholder to reduce vibration.

8. Improper operation of the tool

Cause: If the tool is not replaced in time or misused during operation, it may lead to overuse of the milling cutter and wear or breakage of the cutting edge. In the process of production and processing of titanium alloy casting box and box cover, etc., improper operation such as unreasonable clamping, inappropriate depth of cut, too fast spindle speed, insufficient cooling, etc. will lead to chipping, breaking and fracture of the tool.

Solution:

Regularly check the tool wear and replace or sharpen the tool in time.

Use tool life management system to scientifically manage and monitor the tool.

Hunan Jetvision Industrial Co.Ltd is one of the leading Tungsten carbide manufacturers and suppliers with over 20years experience of tungsten carbide products production and technology, It's a professional supplier which provide kinds of tungsten carbide products, such as carbide milling tool, cemented carbide rod blank, cemented carbide wire drawing dies, tungsten carbide seal rings, tungsten carbide plate, tungsten carbide bushing, carbide tube, tungsten carbide button, carbide mining inserts, carbide blade, tungsten carbide strip, carbide dies, carbide brazed tips, tungsten carbide no standard products, carbide studs, tungsten carbide customized components which are widely used in machinery, mining, construction, oil and drill, industrial engineering etc.

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