What are the causes of blade wear in cutting? How to deal with it?（I）
Flank wear
1. Rapid wear results in poor or out-of-tolerance surface quality.
Reason:
* Excessive cutting speed
* Insufficient wear resistance
* Feeding too low
Solution:
* Reduce cutting speed (VC)
* Choose materials with higher wear resistance
* Raise the feed (fz)
2. Excessive wear leads to short tool life
Reason:
* Vibration
* Chip recutting
* Burrs form on parts
* Surface poor quality
* generate heat
Solution：
* Raise feed (FZ)
* Adopt suitable milling
* Use compressed air for effective chip removal
* Check the recommended cutting parameters
3. Uneven wear causes damage to sharp corners
Reason:
* Tool run out
* Vibration
* Short tool life
* Surface poor quality
* loud noise
Solution:
* Reduce the runout amount to less than 0.02mm
* Check collet and collet
* Minimize tool overhang
* Use fewer teeth for cutting
* Choose a larger tool diameter
* For solid carbide end mills and replaceable head mills, select groove types with larger helical Angle (GP ≥45°)
* Divide axial depth (AP) into multiple cutting knives
* Reduced feed (FZ)
* Improve tool and workpiece clamping
Crater wear
Excessive wear results in reduced cutting edge strength. A broken cutting edge results in poor surface quality
Reason:
The cutting temperature of the front blade surface is too high, which leads to diffusion wear
Solution:
* Choose the alumina coating material
* Choose the groove shape of front Angle blade
* Lower the speed to get a lower temperature, and then lower the feed
