Insert failure can be caused by normal wear of any kind of material. Normal flank wear is the most common wear mode because it is die cast parts the type of tool failure that can be predicted with the greatest accuracy. Wear along the flanks of a cutting tool is typically even and appears gradually as the machining material wears the cutting edge. This process is analogous to the edge's gradual dulling.

When zinc alloy die castings or work-hardened materials contain hard micro-inclusions, normal flank wear can occur when these inclusions cut into the insert. The abrasive wear that occurs during low-speed cutting and the chemical reactions that take place during high-speed cutting are both contributors to this wear. When analyzing normal flank wear, you will notice a relatively uniform wear scar along the cutting edge of the insert. This scar will help you identify normal flank wear. Sometimes the metal on the zinc alloy die casting will scratch the cutting edge, which will give the impression that the wear scar on the blade is much larger than it actually is.

It is important to select the hardest insert material grade that will not chip and to use the lightest cutting edge to reduce the amount of cutting forces and friction in order to slow down the normal flank wear that occurs over time. On the other hand, rapid flank wear is undesirable because it shortens the life of the tool and prevents the achievement of the standard cutting time of 15 minutes. In the process of cutting wear-resistant materials, such as ductile iron castings, aluminum alloy die castings, zinc alloy die castings, superalloys, deposition hardening (PH) stainless steel after heat treatment, beryllium copper alloy, and tungsten carbide, as well as cutting non-metallic materials, such as fiberglass, epoxy, reinforced plastics, and ceramics, often exhibit rapid wear.

The telltale signs of rapid flank wear are the same as those of normal wear. It is essential to choose a wear-resistant, stronger, or coated carbide insert material grade in order to correct rapid flank wear, and it is also essential to make sure that the appropriate coolant is being used. Reducing the cutting speed is also an extremely effective strategy; however, it is not appropriate for production needs because it will have a negative impact on the processing cycle of zinc alloy die castings. This will make it unsuitable for production. Craters are caused by the thermal and chemical reactions that occur when an insert dissolves into the workpiece chips during high-speed machining operations of iron-based or titanium-based alloys. These operations are typically performed at high speeds.

Craters are formed through the combined die casting aluminum efforts of abrasive wear and dispersive wear. During the process of machining base alloys and titanium-based alloys, the heat generated in the chips produced by the workpiece will dissolve and disperse the components of the cemented carbide into the chips. This will result in the formation of craters on the top of the insert. The crater will eventually grow to such a size that the flank will chip, deform, and possibly experience rapid wear.

Built-up edge is produced when fragments of the workpiece are bonded to the cutting edge through the process of thermocompression. This process is brought about in the cutting zone by chemical affinity, high pressure, and high temperature. Chipping and rapid flank wear will result from the built-up edge eventually falling off, sometimes along with the blade fragments. This type of failure mechanism occurs frequently in materials that are viscous, when the speed of the process is low, when the temperature of the alloy is high, in stainless steel and non-ferrous materials, and in threading and drilling. Built-up edge can be recognized by abnormal changes in the size or surface roughness of zinc alloy die castings, as well as by the appearance of shiny materials on either the top or the flank of the cutting edge.

Built-up edge can be managed by increasing the cutting speeds and feeds, employing inserts with nitride coatings, making strategic use of coolant, and using inserts with force-reducing geometry and/or smooth surfaces. Chipping is the result of mechanical instability, which is typically the result of loose clamping, poor bearings or worn spindles, hard spots in the material being machined, or interrupted cutting. Chipping can also be caused by hard spots in the material being machined. When machining powder metallurgy (PM) materials, for example, which are designed to intentionally leave a porous structure on the part, this phenomenon can sometimes appear in the most unexpected of places. Localized stress concentrations and possible chipping can be caused by solid inclusions on the surface of the cutting material as well as by cuts that are interrupted.

When this failure mode occurs, there is a very noticeable chip distribution along the cutting edge of the insert. Chipping can be avoided by ensuring that the machine is properly set up, minimizing warping, utilizing ground inserts, controlling built-up edge, selecting an insert material grade that is more durable, and either choosing a stronger cutting edge geometry or a more durable cutting edge geometry. The failure of a thermomechanical system can be caused by severe shifts in temperature as well as mechanical shocks. Along the edge of the blade, stress cracks start to form, and eventually, the carbide that makes up the blade starts to fall away, creating an effect that is similar to chipping.

Milling operations, as well as facing and machining operations that use intermittent coolant, are the most likely to result in thermomechanical failure. There is also a possibility of thermomechanical failure occurring in intermittent turning of high-volume parts. The presence of multiple cracks that run perpendicular to the cutting edge is evidence that the material has failed due to thermomechanical stress. It is of the utmost importance to identify this failure mode before the onset of microcraving. Thermomechanical failure can be avoided by properly utilizing coolant, or, if it is desired to completely eliminate this failure in the machining process, by utilizing more impact-resistant material grades and geometries that reduce heat generation and reduce feed rates. Both of these strategies can be utilized in order to completely eliminate this failure in the machining process.

Edge deformation can be traced back to excessive heat as well as mechanical loads. A great deal of heat is typically produced when machining hard steel, work-hardened zinc alloy die-casting surfaces, and superalloys. High speeds and high feeds also have a tendency to generate a great deal of heat. If there is an excessive amount of heat, the carbide bond or the cobalt in the insert may become pliable. When stress from the insert and the workpiece causes the insert to deform or the tip to sink, this is an example of mechanical loading. Over time, mechanical loading can lead to the insert breaking or rapid flank wear.

Cutting edge deformation is included among the traces of edge deformation, and the processed workpiece does not meet the dimensional specifications that were specified. The following methods can be used to control the deformation of the cutting edge: appropriate use of coolant; use of more wear-resistant material grades with lower binder content; reduction of processing speed and feed rate; and selection of grooves that reduce cutting forces. All of these methods require reasonable use of coolant. The rough zinc alloy die casting surface can cause notch wear on the tool if it abrades and scores deep into the cutting zone. Notch wear can be caused by surfaces that have been cast, oxidized, work-hardened, or that are irregular.

Even though abrasive wear is the most common cause of damage in this region, chipping is still a possibility here. The insert depth-of-cut line is typically subjected to tensile stress, making it susceptible to failure. When notch wear and chipping start occurring at the depth of cut of the insert, you will notice this mode of failure for the first time. Increase the cutting speed, decrease the feed rate when working with superalloys, and die casting manufacturer carefully increase the grinding at the depth of cut to prevent chip buildup. This is especially important when machining stainless steel and superalloys. Changing the depth of cut in multi-stroke machining, using a tool with a larger rake angle, increasing the cutting speed, and increasing the rake angle of the tool are the keys to preventing groove wear.