Analysis of Wear Causes of Broken Carbide Milling Blades

Formed carbide milling cutters are widely used due to their small shape tolerances. Because the inserts cannot be directly replaced, most of the milling cutters are scrapped after chipping, which greatly increases the processing cost.

1. Processing material properties

When cutting titanium alloys, due to the poor thermal conductivity of titanium alloys, chips are easily adhered to the vicinity of the cutting edge of the tool tip or form a built-up edge, and a high temperature zone is formed on the front and flank surfaces near the tool tip, causing the tool to lose its red hardness and wear. exacerbated. In continuous cutting under high temperature conditions, the bond and weld are impacted by subsequent processing, and part of the tool material will be taken away during the forced flushing process, resulting in tool defects and damage. In addition, when the cutting temperature reaches above 600 °C, a hardened hard layer will be formed on the surface of the part, which will have a strong wear effect on the tool. Titanium alloy has low elastic modulus, large elastic deformation, and large amount of rebound of the workpiece surface near the flank, so the contact area between the machined surface and the flank is large, and the wear is serious.

2. Normal wear and tear

In normal production and processing, when the allowance of continuous milling titanium alloy parts reaches 15mm-20mm, there will be serious blade wear. Continued milling is extremely inefficient, and the surface finish of the workpiece is poor to meet production and quality requirements.

3. Improper operation

In the process of producing and processing titanium alloy casting boxes and box covers, improper operations such as unreasonable clamping, unsuitable cutting depth, too fast spindle speed, and insufficient cooling will lead to tool chipping, breakage, and breakage. In addition to being unable to perform effective milling, such defective milling cutters will also cause surface defects such as concave surfaces on the machined surface due to "gnawing cutters" during the milling process, which not only affects the machining quality of the milling surface, but also causes the workpiece to be scrapped in severe cases.