| Tool wear/breakage patterns | Phenomenon | reason | solution |
| Flank wear | The cutting resistance increases and groove wear gradually forms on the flank surface. Surface quality deteriorates or size exceeds tolerances | The tool material is too soft. The cutting speed is too high. The clearance angle is too small. The feed amount is too small. | Select tool materials with high wear resistance, reduce cutting speed, increase clearance angle, and increase feed rate |
| rake face wear(crater wear) | Poor chip breaking control, deterioration of finished surface, occurs when machining carbon steel at high speed | The tool material is too soft. The cutting speed is too high. The feed rate is too large. The geometry strength is too small. | Choose high wear-resistant tool materials, reduce cutting speed, reduce feed, and choose stronger insert geometries. |
| chipping flute | Sudden edge chipping (front and rear blade surfaces) and unstable tool life | The tool material is too hard, the feed rate is large, the cutting edge strength is insufficient, and the tool shank and tool holder are not rigid enough. | Choose tool materials with good toughness, reduce the feed rate and increase the amount of edge grinding (chamfering instead of rounding), increase tool rigidity and main deflection angle |
| Broken blade | Increased cutting resistance and worsened surface roughness | The tool material is too hard, the feed rate is large, the cutting edge strength is insufficient, and the tool shank and tool holder are not rigid enough. | Choose tool materials with good toughness, reduce the feed rate and increase the amount of edge grinding (chamfering instead of rounding) to improve the rigidity of the workpiece and tool. |
| Plastic deformation (blade collapse) | Changes in the size of the workpiece, wear of the tool tip, wrinkles or dullness of the blade, machining of alloy steel Ansheng | The tool material is too soft, the cutting speed is too high, the cutting depth is too high, and the feed rate is too large. The cutting edge temperature is too high. | Select tool materials with high wear resistance to reduce cutting speed, reduce cutting depth and feed rate, and select tool materials with high thermal conductivity (CVD and confiscated cutting fluid). |
| Built-up edge (adhesive) | The workpiece material is fused to the cutting edge of the tool and the finishing surface deteriorates. Cutting resistance increases and soft materials are processed. | The cutting speed is reduced and the cutting edge is not sharp. The tool material is not suitable. | Increase cutting speed and increase rake angle Choose tool materials with low affinity (coating, cermet, etc.) |
| Thermal cracking | Breakage due to thermal cycling (mostly seen in milling and interrupted cutting) | Tool material is excellent Expansion and contraction caused by cutting heat (hot and cold rings) |
Thousand-type cutting or provide sufficient coolant and choose tool materials with good toughness and resistance to thermal shock. |
| Peel off | It often occurs in cutting of high | Local failure at deep cutting depth, local chipping and local craters | Work hardened materials, scale, high temperature alloys, etc. Increase the rake angle to sharpen the cutting edge and enlarge the insert chip groove. |
| Groove wear at depth of cut | hardness materials and vibration. | The bonded cutting on the cutting edge is not discharged smoothly | Use high wear-resistant CVD coating materials and use tapered chips (variable depth of cut) to reduce the main deflection angle |
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