Tool Chipping

2) Chipping of cutting edge or tip

This type of damage often occurs under cutting conditions that are more
severe than those that cause chipping of the cutting edge, or is a further
development of chipping. The size and scope of the collapse are larger than
that of the micro collapse, so that the tool completely loses the cutting ability
and has to stop working. The broken tip of a knife is often referred to as tip
drop.

Causes And Solutions Of Tool Chipping

1) The blade grades and specifications are improperly selected, such as the
thickness of the blade is too thin or the grades that are too hard and brittle are
selected for rough machining.

Solutions: Increase the thickness of the blade or install the blade upright, and
choose a grade with higher bending strength and toughness.

2) Improper selection of tool geometry parameters (such as too large front and
rear angles, etc.).

Solutions: The tool can be redesigned from the following aspects.

① Reduce the front and rear angles appropriately.

② Use a larger negative blade inclination angle.

③ Reduce the entering angle.

④ Use larger negative chamfer or cutting edge arc.

⑤ Sharpen the transition cutting edge to enhance the tool tip.

3) The welding process of the blade is incorrect, causing excessive welding

stress or welding cracks.

Solutions:
①Avoid using a blade slot structure with three sides closed.

② Correctly select solder.

③Avoid using oxyacetylene flame to heat welding, and keep warm after
welding to eliminate internal stress.

④ Use mechanical clamping structure as much as possible.

4) Improper sharpening method will cause grinding stress and grinding cracks;
after sharpening the PCBN milling cutter, the vibration of the teeth is too large,
which will overload the individual teeth and cause the knife to hit.

Solutions:

①Use intermittent grinding or diamond wheel grinding.

②Choose a softer grinding wheel and dress it frequently to keep the grinding
wheel sharp.

③Pay attention to the quality of sharpening, and strictly control the vibration
of the cutter teeth.

5) The selection of cutting amount is unreasonable. If the amount is too large,

the machine will become stuffy; when intermittent cutting, the cutting speed is
too high, the feed rate is too large, and the blank margin is uneven, the cutting
depth is too small; cutting high manganese steel For materials with high work
hardening tendency, the feed rate is too small, etc.

Countermeasure: Reselect the cutting amount.

6) Structural reasons such as the uneven bottom surface of the slot of the
mechanical clamping tool or the excessively extended blade.

Solutions:

① Trim the bottom surface of the knife groove.

② Reasonably arrange the position of the cutting fluid nozzle.

③The hardened shank adds a hard alloy gasket under the blade.
7) Excessive tool wear.

Solutions: Change the tool or the cutting edge in time.

8) The cutting fluid flow is insufficient or the filling method is incorrect, which
causes the blade to be hot and cracked.

Solutions:

① Increase the flow of cutting fluid.

② Arrange the position of the cutting fluid nozzle reasonably.

③ Use effective cooling methods such as spray cooling to improve the

cooling effect.

④ Use * cutting to reduce the impact on the blade.

9) The tool is installed incorrectly, such as: the cutting tool is installed too high
or too low; the face milling cutter uses asymmetric down milling, etc.

Countermeasure: Reinstall the tool.

10) The rigidity of the process system is too poor, resulting in excessive
cutting vibration.

Solutions:

① Increase the auxiliary support of the workpiece to improve the rigidity of the
workpiece clamping.

② Reduce the overhang length of the tool.

③ Appropriately reduce the clearance angle of the tool.

④ Use other anti-vibration measures.

11) Careless operation, such as: When the tool cuts in from the middle of the
workpiece, the action is too violent; the tool has not been retracted, and it
stops immediately.
Countermeasure: Pay attention to the operation method.