Wear analyzer

How to use the wear analyzer

Select the type of wear in the tab at the top, specify the workpiece material, operation, symptom and cooling condition - the tool will determine the main cause and provide step-by-step recommendations for correcting modes.

Three types of wear:

• Rear edge—uniform abrasion of the rear surface of the plate. The most common type of wear, the main reason is excessive cutting speed and temperature.
• Crater—a depression on the front face in the area of ​​contact with the chips. Sign of thermal destruction: the temperature melts the carbide bond.
• Chipping—chipping and destruction of the cutting edge. Mechanical wear from vibrations, shocks and system instability.

Features by materials

Stainless steel (group M) is prone to work hardening and built-up build-up (BUE) - requires sharp geometry and lubricating coolant. Heat-resistant alloys and titanium (group S) have low thermal conductivity - heat goes into the tool, not into the chips. A coated carbide and high coolant pressure are required. Hardened steels (group H) are processed only with CBN or special class H carbide at maximum system rigidity.

Frequently Asked Questions

The tool wears differently on different teeth - what does this mean? Uneven wear along the teeth is a sign of runout of the cutter or uneven clamping. Check the chuck for runout and replace or rebalance the chuck.

Is it possible to work longer without changing the insert? An overblown tool works with even greater temperature and load - wear increases like an avalanche, and the quality of the surface decreases. Replacing a plate according to regulations is always cheaper than repairing a part or spindle.

Which symptom should you choose if several are visible at once? Choose the dominant one - the one that appears first or is most pronounced. The analyzer will give recommendations on the main reason, the rest are often eliminated along the way.

Do you need to select plates or tools for a specific material and operation? We will help you choose from the catalog.

The chips are long, but the hole turns out fine—does anything need to be changed? Yes. Long chips pose a risk of wrapping around the tool or workpiece, causing operator hazards and causing process instability. Even if the size is now within the tolerance, if the batch of workpieces is changed or the edge becomes dull, long chips will lead to an accident. Solution: increase the feed or change the geometry of the chipbreaker.

Chips turn blue when drilling deep holes - what to do? Blue color means overheating. The main reasons: the coolant does not reach the cutting zone, the grooves are clogged with chips, the speed is too high. The first step is to provide coolant through the tool or HPC. The second is to reduce Vc by 15–25%. The third is to check the dullness of the edge.

What is BUE and why is it a problem? BUE (Built-Up Edge) is a build-up on the cutting edge: the workpiece material is “welded” to the tool under pressure and temperature. The build-up periodically breaks off along with a particle of the edge, leaving marks on the surface of the part and accelerating wear. Typical for stainless steel and aluminum at low cutting speeds. Solution: Increase Vc, add lubricating coolant, use polished rake geometry or DLC coating.

At what L/D do you need to switch to through-tool coolant? General recommendation: with L/D > 5, coolant supply through the tool is desirable, with L/D > 8 it is mandatory. Without internal feed, when deep drilling, chips are packed in the grooves, the torque increases - and the drill breaks.

How do you understand that the chipbreaker is not working? If the chips come out in a long ribbon, spiral, or wound, the chipbreaker does not work. Three reasons: feed below the minimum operating range of the chipbreaker, depth of cut (ap) is out of range, or the geometry is not suitable for the material. Check the working area of ​​the chipbreaker in the manufacturer's catalog - it is listed as the ap × f range.

Problems with chip formation, selection of geometry or modes? We will select a tool and strategy for your operation - contact our specialists.

How to use chip diagnostics

Select a group of symptoms (shape / temperature / extension / surface), indicate the specific symptom, operation, ISO material and type of cooling - the calculator will determine the level of risk, show what to pay attention to first and give step-by-step recommendations based on your situation. When drilling, additionally specify the L/D ratio - depth affects chip removal and the risk of bunching.

Why chips are the main indicator of the process

The chips are the only element that leaves the cutting zone and is visible to the operator in real time. By its shape, color and behavior, you can determine the problem before it leads to defective or broken instruments.

Normal chips are short (C-shaped or “comma”), uniform in color, and flow freely from the cutting zone. Any deviation is a signal: a long tape means that the chipbreaker is not working; blue color indicates overheating; sticking (BUE) indicates improper speed or lack of lubrication; clogged drill grooves are a recipe for failure in the next few seconds.

What influences chip formation

Feed (f / fz). The main parameter of the chipbreaker. Too low a feed produces thin, long chips that do not break - the tool “rubs” instead of cutting. Increasing the feed to the lower end of the recommended range will often solve the problem immediately.

Cutting speed (Vc). Affects the temperature and ductility of the material in the cutting zone. At low Vc, built-up edge (BUE) forms on stainless steel and aluminum - the material “sticks” to the edge. When Vc is too high, the chips turn blue, the edge overheats, and the tool life drops significantly.

Tool geometry. The chipbreaker works in a certain range of ap and f. If the parameters are outside this range, the chipbreaker does not break chips, even if there is one. Sticky materials (Groups M, N) require a sharp geometry with a large rake angle and polished grooves.

Cooling and removal. The coolant performs two functions: it cools the cutting zone and washes away chips. When drilling with L/D > 5 without internal coolant supply (through-tool), the chips do not come out of the hole - bunching and breakage occurs. HPC (high pressure) is critical for deep holes and high temperature alloys.

Workpiece material: Stainless steel (M) and heat-resistant alloys (S) produce viscous, long chips that are prone to sticking. Cast iron (K) - short but abrasive. Aluminum (N) - plastic and “sticky”. Hardened steels (H) - brittle, fine, abrasive. Each group requires its own chip formation strategy.

Hole depth (L/D). When L/D > 8, chip removal becomes the main problem. Coolant pressure, cycle type (G73/G83), chip shape, and condition of the coolant passages determine whether chips will exit the hole or jam the tool.