Optimizing Insert Life 305

Metal Cutting Training

Class Information

ToolingU.com classes are offered at the beginner, intermediate, and advanced levels. The typical class consists of 12 to 25 lessons and typically requires at least two hours of instruction time.

Class Name:	Optimizing Insert Life 305
Description:	This class describes common forms of insert wear that lead to insert failure and identifies the appropriate control methods for each type. Includes an Interactive Lab.
Prerequisites:	200200 200220 200240
Difficulty:	Advanced
Number of Lessons:	15
Language:	English, Spanish

Below are all the competencies and job programs that contain the class Optimizing Insert Life 305. Job programs are our traditional class lists organized according to common job functions. Competencies are our latest job-specific curricula that help tie online learning to practical, hands-on tasks.

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Competencies
CNC Machinist CNC Programmer Toolroom Machinist

Class Outline
Objectives The Economics of Insert Life Tool Wear Flank Wear Premature Flank Wear Crater Wear Notch Wear Built-Up Edge Plastic Deformation Thermal Cracking Chipping Chip Hammering Fracture The Role of the Operator Summary

Class Objectives
Describe the economics of insert life. List the types of tool wear. Identify flank wear. Identify the variable that affects insert life the most. Identify crater wear. Identify notch wear. Identify a built-up edge. Identify plastic deformation. Identify thermal cracking. Identify chipping. Identify chip hammering. Identify fracture. Describe the role of the operator in extending insert life.

Class Vocabulary
adhesion		The build up of workpiece material on an insert during metal cutting.
aluminum oxide		A common coating element for carbide tools that has excellent resistance to crater wear and notching.
built-up edge		Adhesion of workpiece material to the cutting edge of an insert due to high temperatures and pressure welding. Built-up edge is a common cause of tool failure when machining soft, gummy metal.
chatter		The occasional vibration between a workpiece and a cutting tool. Chatter decreases machining productivity, negatively impacts surface quality, and increases tool wear.
chip hammering		Tool wear characterized by damage to the insert's rake face due to the constant chiseling action of long chips.
chip load		The thickness of a chip generated during a machining operation.
chipbreaker		A feature designed to prevent chips from forming into long pieces. Chipbreakers are either indentations on the surface of the cutting insert or another wafer clamped above the insert in the toolholder.
chipping		Tool wear resulting in the loss of small slivers from the cutting edge of the tool. Chipping is also called frittering.
clearance		An amount of space or distance between two objects.
clearance angle		The angle designed to eliminate interference and provide adequate space between the cutting tool and the workpiece.
corner radius		The rounded tip on the cutting edge of an insert. The greater the corner radius, the greater the degree of roundness at the tip. A zero degree corner radius creates a sharp point.
crater wear		Tool wear characterized by a concave depression in the rake face of the cutting tool adjacent to the cutting edge. Crater wear is also called cratering.
cratering		Tool wear characterized by a concave depression in the rake face of the cutting tool adjacent to the cutting edge. Cratering is also called crater wear.
depth of cut		The distance that the cutting tool is plunged into the workpiece. Depth of cut is typically measured in millimeters or inches.
depth-of-cut notching		Insert wear characterized by excessive localized damage on both the rake face and flank of the insert at the depth-of-cut line. Depth-of-cut notching is also called notch wear and notching.
diffusion		The wearing away of material due to the exchange of atoms.
ductile		Able to bend, stretch, or form without breaking. Ductile metals tend to produce long, continuous chips.
edge hone		A rounded and blunted cutting edge used to add strength.
feed rate		The rate at which the cutting tool and the workpiece move in relation to one another. Feed is typically a linear movement.
fissures		Small cracks perpendicular to the cutting edge of an insert that appear due to high temperatures.
flank		The flat surface of an insert perpendicular to the rake face.
flank wear		Tool wear resulting in the gradual wearing away of the cutting edge. Flank wear is mostly caused by abrasion, is predictable, and is the most desired form of tool wear.
fracture		The catastrophic failure of the insert due to the separation of a large section. Fracture can happen without warning or as the result of other forms of insert wear.
frittering		Tool wear resulting in the loss of small slivers from the cutting edge of the tool. Frittering is also called chipping.
hone		A rounded and blunted cutting edge shaped by abrasives. The hone on a cutting edge increases edge strength.
indexing		Rotating a carbide insert to present a new cutting edge. Once all the cutting edges are worn, the insert is replaced.
insert		An indexable and replaceable cutting tool with a geometric shape that has multiple cutting surfaces.
intermittent cut		Metal cutting during which one or more edges of the cutting tool are not in constant contact with the workpiece surface. Milling is an intermittent cutting operation.
lead angle		The approach angle of the cutting edge as it enters the workpiece. The lead angle controls the direction of the radial and axial cutting forces.
mechanical wear		Insert wear caused by intense physical contact between an insert and a workpiece.
notch wear		Insert wear characterized by excessive localized damage on both the rake face and flank of the insert at the depth-of-cut line. Notch wear is also called notching and depth-of-cut notching.
oxidation		A chemical reaction involving the addition of oxygen, the removal of hydrogen, or the removal of electrons from an element or compound.
plastic deformation		Permanent deformation of the tool that occurs during metal cutting because of extreme pressure, extreme temperature, and intense mechanical contact. Plastic deformation is also called thermal deformation.
rake angle		An angle describing the tilt of the face from the cutter axis or radius. Positive rake angles reduce cutting forces and encourage chip removal.
relief		A clearance angle behind or below the cutting edge that allows the tool to be forced into the workpiece material.
speed		The rate at which the cutting edge of the tool moves past the workpiece surface at the point of contact. Speed is typically a rotational movement.
tantalum carbide		A material used in carbide cutting tools that offers improved hot hardness and reduced thermal deformation.
thermal cracking		Insert wear characterized by small cracks and fissures caused by temperature fluctuations. Thermal cracking is also called thermal fatigue.
thermal deformation		Permanent metal deformation that occurs during metal cutting because of extreme pressure, extreme temperature, and intense mechanical contact. Thermal deformation is also called plastic deformation.
thermal fatigue		Insert wear characterized by small cracks and fissures caused by temperature fluctuations. Thermal fatigue is also called thermal cracking.
titanium carbide		TiC. A material used to make carbide cutting tools that offers improved chemical stability and crater resistance.
tungsten carbide		The original carbide tool material. Tungsten carbide offers excellent hardness. However, it is somewhat expensive and tends to crater when machining steel.
wear land		The flattened section that forms on the flank of the tool behind the cutting edge due to abrasive wear with the workpiece.
work harden		To increase the hardness of a workpiece exterior due to temperature and pressure at the point of contact.