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What are the four main types of tool wear? Uncover the mystery of each!
In the field of machining, tool wear is the gradual failure of cutting tools due to frequent operation. Tools affected by this phenomenon include belt cutters, cutters and drills, which are an integral part of the machine manufacturing process. This article will explore the four main types of tool wear, including side wear, concave wear, notch wear, and stacked edges, and reveal their causes and characteristics.
Side wear
Side wear refers to the gradual wear of the part where the tool is in contact with the machined part. This wear is usually most noticeable during cutting, where side wear occurs when the cutting tool first begins to lose its standard geometry. The effects of this form of wear increase over time and may eventually lead to a reduction in the cutting performance of the tool.
Side wear will increase cutting forces and affect the surface finish and processing accuracy after processing.
Concave wear
Concave wear mainly occurs on the cutting edge of the tool, especially when the contact surface between the tool and the chip rubs. This wear is usually normal, but when it becomes severe enough to cause edge failure, it can affect the tool's ability to function properly. The depth of concave wear will be approximately equal to the depth of cut.
Concave wear is mainly caused by the spindle speed being too low or the feed speed being too high.
Notch wear
Notch wear develops between the face and side of a tool and is usually localized damage caused by chips being pressed onto the tool during machining. This wear reduces the tool's effective cutting ability, so its effects require special attention.
If not treated in time, notch wear may affect processing accuracy and production efficiency.
Stacked edges
Building edge refers to the tendency of processing material to adhere to the cutting edge of the tool during cutting. This phenomenon is particularly evident in the processing of flexible metals such as aluminum and copper. This wear can be reduced by increasing cutting speed and using lubricants.
Effects of wear
Common effects of tool wear include:
- Increase cutting force
- Increase cutting temperature
- Poor surface finish
- Reduce the accuracy of machined parts
- May cause tool damage
Reducing tool wear can be achieved through the use of lubricants and coolants, which help reduce friction and temperature.
When processing, temperature factors and energy input also need to be considered, because concave wear in high-temperature areas will significantly increase, and 80% of the energy is taken away through chips, thereby reducing the speed of tool wear during processing. .
Conclusion
By understanding the main types of tool wear and their impact on the machining process, companies can develop more effective usage strategies to extend tool life. But the question is, can we find the best balance to maximize the effectiveness and longevity of our tools?
