Tool Wear

Tool wear describes the gradual failure of cutting tools due to regular operation. It is a term often associated with tipped tools, tool bits, or drill bits that are used with machine tools.

Types of wear include:

• flank wear in which the portion of the tool in contact with the finished part erodes. Can be described using the Tool Life Expectancy equation.
• crater wear in which contact with chips erodes the rake face. This is somewhat normal for tool wear, and does not seriously degrade the use of a tool until it becomes serious enough to cause a cutting edge failure.

Can be caused by spindle speed that is too low or a feed rate that is too high. In orthogonal cutting this typically occurs where the tool temperature is highest. Crater wear occurs approximately at a height equaling the cutting depth of the material. Crater wear depth ~ t₀ t₀= cutting depth

• built-up edge in which material being machined builds up on the cutting edge. Some materials (notably aluminum and copper) have a tendency to anneal themselves to the cutting edge of a tool. It occurs most frequently on softer metals, with a lower melting point. It can be prevented by increasing cutting speeds and using lubricant. When drilling it can be noticed as alternating dark and shiny rings.
• glazing occurs on grinding wheels, and occurs when the exposed abrasive becomes dulled. It is noticeable as a sheen while the wheel is in motion.
• edge wear, in drills, refers to wear to the outer edge of a drill bit around the cutting face caused by excessive cutting speed. It extends down the drill flutes, and requires a large volume of material to be removed from the drill bit before it can be corrected.