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Causes and solutions for fast tool wear
The rapid advancement of modern science and technology has not only driven the continuous evolution of CNC machining equipment but also significantly boosted the progress of cutting techniques. As production demands grow increasingly sophisticated and automated, the materials used in tools have undergone transformative changes. Today, tools crafted from advanced materials like titanium alloys, carbon fiber composites, and ultra-high-temperature resistant metals continue to emerge, elevating tool quality and improving critical factors such as reliability, precision, and lifespan.
One of the most significant challenges in tool usage lies in wear, which manifests in several distinct ways during mechanical operations. First, wear can result from mechanical forces, such as abrasion or scraping. Second, excessive heat generated during cutting can lead to adhesion and diffusion issues. Third, exposure to certain chemical elements may cause the cutting edge to soften and melt. Let us now delve deeper into the causes of each type of wear:
(1) Mechanical Action-Induced Wear: Difficult-to-machine materials pose a unique challenge since their poor thermal conductivity accelerates tool degradation. At elevated temperatures, the adhesive strength within the tool material diminishes, hastening wear.
(2) Temperature-Related Wear: Cutting tough and hard materials often results in excessively high cutting-edge temperatures, leading to tool wear. In particular, when working on materials that produce short chips, crescent-shaped wear occurs near the cutting edge, drastically reducing tool longevity.
(3) Chemical Wear: Specific elements in tool materials can chemically interact with the workpiece material under certain conditions, causing the tool coating to degrade or transform into other substances. This accelerates wear and tool failure.
When selecting a cutting tool, several performance criteria must be met. First, wear resistance is paramount; different tools vary widely in quality, ranging from basic carbon steel to premium diamond-tipped tools. Second, impact resistance ensures durability, particularly in high-speed applications where thermal hardness and chemical stability are crucial. Lastly, tool lifespan can be extended by applying heat-resistant coatings or multi-layer treatments to enhance cutting efficiency.
In terms of material selection, alloy tool steels excel in high-temperature hardness and are commonly used for intricate, low-speed tools like reamers and taps. High-speed tool steel combines high-temperature hardness, wear resistance, and excellent heat treatment properties, making it ideal for general-purpose tools such as turning tools and drills. Cemented carbide, an alloy produced via powder metallurgy using carbides, titanium carbides, and cobalt, represents one of the most popular tool materials today due to its exceptional hardness and durability.
As manufacturing technologies evolve, the demand for advanced tooling solutions continues to rise. By addressing wear mechanisms and optimizing material choices, manufacturers can ensure tools meet the rigorous demands of modern CNC machining. This ongoing innovation underscores the dynamic relationship between technological progress and tool development.
Reprinted from the Global CNC Tool Network