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    车削-切槽刀片 & 切断刀片磨损原因及解决方案

    车削-切槽刀片
    切断
    端面切槽

    磨损类型
      • ×
        后刀面磨损
        后刀面磨损
        原因
        • 切削速度高
        • 硬质合金牌号不耐磨

        解决方案
        • 降低切削速度
        • 采用耐磨性更佳的牌号
        • 提高冷却液压力
        • 调整刀片中心高度
      • ×
        月牙洼磨损
        月牙洼磨损
        原因
        • 刀片切削区域切削温度过高，压力过大

        解决方案
        • 降低切削速度
        • 降低进给率
        • 采用耐磨性更佳的牌号
        • 提高冷却液压力
        • 采用带大正前角的刀片
      • ×
        塑性变形
        塑性变形
        原因
        • 切削温度过高

        解决方案
        • 降低切削速度
        • 降低进给率
        • 采用耐磨性更佳的牌号
        • 提高冷却液压力
      • ×
        沟槽磨损
        沟槽磨损
        原因
        • 切削速度过高，或刀片牌号不耐磨

        解决方案
        • 降低切削速度
        • 降低进给率
        • 采用耐磨性更佳的牌号
        • 调整切削深度
        • 提高冷却液压力
      • ×
        热裂
        热裂
        原因
        • 切削区域表面温度变化太大，断续切削，或冷却液供应产生变化

        解决方案
        • 降低切削速度
        • 降低进给率
        • 采用韧性更佳的牌号
        • 采用更强固的切削刃
        • 断续切削时停止供应冷却液
      • ×
        切削刃破损
        切削刃破损
        原因
        • 更换刀片切削刃前，刀片过度磨损
        • 对于该应用而言，刀片牌号及几何形状都太弱了
        • 刀片载荷过大
        • 刀片已形成了积屑瘤

        原因
        • 降低切削速度
        • 采用韧性更佳的牌号
        • 降低进给率
        • 采用更强壮的刀体
        • 采用更强固的负前角刀片
        • 采用螺钉夹持式替代自夹式
        • 调整刀片中心高度
        • 减小刀具悬伸
      • ×
        积屑瘤
        积屑瘤
        原因
        • 切削区域温度太低
        • 负型刀片
        • 加工材料粘性高，如低碳钢，不锈钢及铝

        解决方案
        • 提高切削速度
        • 采用带锋利切削刃的可转位刀片
        • 提高冷却液压力
      • ×
        Flank Wear
        Flank Wear
        Cause
        • High cutting speed
        • Low wear resistance carbide grade

        Remedy
        • Reduce cutting speed
        • Use harder grade
        • Increase coolant pressure
        • Adjust center height position
      • ×
        Crater Wear
        Crater Wear
        Cause
        • Excessive cutting temperatures and pressures on the top of the insert.

        Remedy
        • Use harder grade
        • Reduce cutting speed
        • Increase coolant pressure
        • Use an insert with a positive cutting rake
      • ×
        Plastic Deformation
        Plastic Deformation
        Cause
        • Cutting temperature is too high

        Remedy
        • Use harder grade
        • Reduce feed rate
        • Reduce cutting speed
        • Increase coolant pressure
      • ×
        Notch Wear
        Notch Wear
        Cause
        • Cutting speed too high, or insufficient insert wear resistance of the carbide grade

        Remedy
        • Reduce the cutting speed
        • Use harder grade
        • Use reinforced cutting edge negative cutting rake
        • Adjust center height position
        • Increase the coolant pressure
      • ×
        Thermal Cracking
        Thermal Cracking
        Cause
        • Excessive variations in surface temperature, intermittent machining, or variations in coolant supply

        Remedy
        • Reduce cutting speed
        • Reduce feed rate
        • Use tougher grade
        • Use stronger edge geometry
        • Turn off coolant supply when machining interrupted cuts
      • ×
        Edge Fracture
        Edge Fracture
        Cause
        • Caused by excessive insert wear before indexing the insert
        • The grade and geometry could be too weak for the applications
        • Excessive load on the insert
        • Built-up edge has been formed on the insert

        Remedy
        • Reduce the cutting speed
        • Use tougher grade
        • Reduce feed rate
        • Reduce tool extension
        • Use more stable tool holder
        • Use reinforced cutting edge negative cutting rake
        • Use screw clamping instead of self clamping
        • Check center height position
        • Use screw clamping instead of self- clamping
      • ×
        Built-up Edge
        Built-up Edge
        Cause
        • Cutting zone temperature is too low
        • Negative cutting geometry
        • Machining of very sticky materials such as low-carbon steel, stainless steels, and aluminum

        Remedy
        • Increase the cutting speed
        • Use an insert with a positive cutting rake
        • Increase the coolant pressure
      • ×
        Flank Wear
        Flank Wear
        Cause
        • High cutting speed
        • Low wear resistance carbide grade

        Remedy
        • Reduce cutting speed
        • Use harder grade
        • Increase coolant pressure
        • Adjust center height position
      • ×
        Crater Wear
        Crater Wear
        Cause
        • Excessive cutting temperatures and pressures on the top of the insert.

        Remedy
        • Use harder grade
        • Reduce cutting speed
        • Increase coolant pressure
        • Use an insert with a positive cutting rake
      • ×
        Plastic Deformation
        Plastic Deformation
        Cause
        • Cutting temperature is too high

        Remedy
        • Use harder grade
        • Reduce feed rate
        • Reduce cutting speed
        • Increase coolant pressure
      • ×
        Notch Wear
        Notch Wear
        Cause
        • Cutting speed too high, or insufficient insert wear resistance of the carbide grade

        Remedy
        • Reduce the cutting speed
        • Use harder grade
        • Use reinforced cutting edge negative cutting rake
        • Adjust center height position
        • Increase the coolant pressure
      • ×
        Thermal Cracking
        Thermal Cracking
        Cause
        • Excessive variations in surface temperature, intermittent machining, or variations in coolant supply

        Remedy
        • Reduce cutting speed
        • Reduce feed rate
        • Use tougher grade
        • Use stronger edge geometry
        • Turn off coolant supply when machining interrupted cuts
      • ×
        Edge Fracture
        Edge Fracture
        Cause
        • Caused by excessive insert wear before indexing the insert
        • The grade and geometry could be too weak for the applications
        • Excessive load on the insert
        • Built-up edge has been formed on the insert

        Remedy
        • Reduce cutting speed
        • Use tougher grade
        • Reduce feed rate
        • Reduce tool extension
        • Use more stable tool holder
        • Use reinforced cutting edge negative cutting rake
        • Check center height
        • Use screw clamping instead of self- clamping
      • ×
        Built-up Edge
        Built-up Edge
        Cause
        • Cutting zone temperature is too low
        • Negative cutting geometry
        • Machining of very sticky materials such as low-carbon steel, stainless steels, and aluminum

        Remedy
        • Increase the cutting speed
        • Use an insert with a positive cutting rake
        • Increase the coolant pressure

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