Accelerated carbide tool wear failure during machining of hot work hardened tool steel: A case study

Abstract

Purpose

The purpose of this paper is to outline and document the failure root cause of a carbide cutting tool during machining of a hardened tool steel under automatic machining conditions.

Design/methodology/approach

Optical metallography and SEM/energy dispersive spectroscopy analysis, together with optical profilometry were employed for failure investigation. The use of an alternative cutting tool and modification of machining conditions are proposed as a failure preventive action.

Findings

Severe abrasive wear and adhesion of machining chips are observed in the flank zone, causing blunting of the cutting edge. The revision of cutting conditions, together with the use CBN-based tool insert leads to an overall improvement of the stability of the process and tool lifetime.

Originality/value

This paper places emphasis on a failure analysis case history following a structured approach in industrial machining problem solving, highlighting suggestions for process improvement.

Citation

Pantazopoulos, G., Toulfatzis, A., Vazdirvanidis, A. and Rikos, A. (2015), "Accelerated carbide tool wear failure during machining of hot work hardened tool steel: A case study", International Journal of Structural Integrity, Vol. 6 No. 2, pp. 290-299. https://doi.org/10.1108/IJSI-07-2013-0013