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Causes and solutions for fast tool wear
The rapid advancement of modern science and technology has not only driven the evolution of CNC machining equipment but also significantly boosted the progress of cutting techniques. As production demands grow increasingly sophisticated and automation becomes more prevalent, the materials used in tool manufacturing have undergone a transformation. New materials like titanium alloys, carbon fiber composites, and ultra-high-temperature resistant alloys have emerged, enhancing tool quality while improving critical attributes such as reliability, precision, and lifespan.
Tool wear is an inevitable issue in machining processes. After prolonged use, tools exhibit various forms of degradation:
1. **Mechanical Action Wear**: Abrasive wear or scuffing occurs due to physical forces.
2. **Heat-Induced Wear**: High temperatures during cutting lead to adhesion and diffusion.
3. **Chemical Wear**: Exposure to certain chemicals causes the tool’s coating to degrade or react chemically.
Each type of wear has distinct causes:
- **Mechanical Wear**: Cutting hard-to-process materials accelerates wear because these materials typically have poor thermal conductivity, reducing the bond strength of the tool's adhesive at elevated temperatures.
- **Temperature-Driven Wear**: Cutting tough, high-hardness materials raises the tool's edge temperature, causing it to soften and wear prematurely, especially when dealing with short-chip workpieces where "crescent wear" can quickly damage the tool.
- **Chemical Erosion**: Specific elements in tool materials can react with processed materials, stripping coatings and hastening tool deterioration.
For effective performance, tools must meet several key criteria:
- **Wear Resistance**: From basic steel to advanced diamond-tipped tools, the disparity in durability is vast. Superior tools often incorporate heat-resistant coatings to extend their lifespan.
- **Impact Strength**: A robust tool requires excellent toughness, especially under high-speed conditions, along with strong thermal and chemical stability.
- **Service Life**: Enhanced coatings improve cutting efficiency and longevity.
Material selection plays a crucial role in tool design:
- **Alloy Tool Steel**: Known for high heat hardness, it’s ideal for intricate, low-speed tools like reamers and taps.
- **High-Speed Steel**: Combining high-temperature resilience with excellent wear resistance, it’s commonly used for standard machine tools like drills and milling cutters.
- **Cemented Carbide**: Made via powder metallurgy using carbides, titanium carbides, and cobalt, this material has become a leading choice due to its superior hardness and wear resistance.
As CNC technology continues to evolve, so too will the demand for innovative tool materials and designs. These advancements ensure that machining processes remain efficient and reliable, meeting the ever-growing complexities of modern manufacturing.
Reprinted from the Global CNC Tool Network