Wear on cutting edges

To understand the advantages and limitations of each material, it is important to have some
knowledge of the different wear mechanisms to which cutting tools are subjected.

Flank wear

Abrasive
The most common type of cutting tool wear and the preferred wear type, as it offers predictable and
stable tool life. Flank wear occurs due to abrasion, caused by hard constituents in the workpiece
material.

Internal - Limited external distribution

 Crater wear

Chemical
Crater wear on the cutting tool is localized to the rake side of the insert. It is due to a chemical
reaction between the workpiece material and the cutting tool and is amplified by cutting speed.
Excessive crater wear weakens the cutting edge and may lead to fracture.

Built-up edge (BUE)

Internal - Limited external distribution

 Adhesive
This cutting tool wear type is caused by pressure welding of the chip to the insert. It is most common
when machining sticky materials, such as low carbon steel, stainless steel and aluminium. Low cutting
speed increases the formation of built-up edge.

Notch wear

Adhesive
Insert wear is characterized by excessive localized damage on both the rake face, and insert flank at
the depth of cut line. Caused by adhesion (pressure welding of chips) and a deformation hardened
surface. A common wear type when machining stainless steels and HRSA.

Internal - Limited external distribution

 Plastic deformation

Thermal
Plastic deformation takes place when the cutting tool material is softened. This occurs when the
cutting temperature is too high for a certain grade. In general, harder grades and thicker coatings
improve resistance to plastic deformation wear.

Thermal cracks

Internal - Limited external distribution

 Thermal
When the temperature at the cutting edge changes rapidly from hot to cold, multiple cracks may
appear perpendicular to the cutting edge. Thermal cracks are related to interrupted cuts, common in
milling operations, and are aggravated by the use of coolant.

Edge chipping/breakage

Mechanical
Chipping or breakage is the result of an overload of mechanical tensile stresses. These stresses can
be due to a number of reasons, such as chip hammering, a depth of cut or feed that is too high, sand
inclusions in the workpiece material, built-up edge, vibrations or excessive wear on the insert.

https://www.sandvik.coromant.com/en-gb/knowledge/materials/pages/wear-on-cutting-edges.aspx

Internal - Limited external distribution