Examples of carbide insert notch wear patterns
Hard alloy insert and cemented carbide insert are widely used in cutting processing. Groove wear is one of the common wear types of these inserts. Specifically, for cemented carbide inserts, it usually manifests as a deep groove wear band formed near the cutting edge. And the same wear phenomenon also often occurs to hard alloy inserts during the cutting operation.
1、Groove Wear
Features: A groove-shaped wear zone that matches the contact area with the workpiece is formed along the main cutting edge or the secondary cutting edge. The depth is obvious and may cause the cutting edge strength to decrease.
Cause: Hard particles in the workpiece material (such as sand holes in castings, carbides in stainless steel) or the work-hardened layer repeatedly rub the cutting edge.
Improper cutting parameters (such as high feed or cutting speed) lead to local high temperatures and mechanical stress concentrations.
2、Example of carbide insert groove wear:
Turning high-temperature alloys (such as Inconel): The same hardness in the material causes the carbide insert cutting edge to groove quickly.
Machining cast iron: Free carbide particles in cast iron intensify cutting edge groove wear.
High feed milling: Grooves are generated near the tool tip due to concentrated feed force.
3、Measures to reduce groove wear
Optimize cutting parameters: reduce feed rate and cutting speed, and reduce mechanical impact.
Select coated carbide inserts: TiAlN or Al₂O₃ coatings can improve resistance to abrasive wear.
Improve cooling: Use high-pressure coolant to flush chips and reduce temperatures.
Insert geometry design: Use large rake angles or enhanced edge treatment (such as chamfering, passivation) to improve edge strength.
Workpiece pretreatment: Remove surface hardening layer or oxide scale (such as rough machining first).
