Why do CNC carbide inserts break?

Why do carbide blades break?

Causes and countermeasures of carbide blade breakage:

1. Improper selection of blade brand and specifications, such as blade thickness is too thin or rough processing is too hard and brittle.

Countermeasures: Increase blade thickness or install blade vertically, and choose brands with higher bending strength and toughness.

2. Improper selection of tool geometry parameters (such as too large front and rear angles, etc.).

Countermeasures: The tool can be redesigned from the following aspects. (1) Appropriately reduce the front and rear angles; (2) Use blades with large negative inclination angles; (3) Reduce the main deflection angle; (4) Use larger negative chamfers or cutting edge arcs; (5) Grind the transition cutting edge to improve the tip of the blade.

3. Incorrect blade welding process causes excessive welding stress or welding cracks.

Countermeasures: (1) Avoid using a three-sided closed slot structure; (2) Select the correct solder; (3) Avoid using oxyacetylene flames to heat and weld, and eliminate internal stress after heat preservation welding; (4) Try to use a mechanical clamping structure

Tungsten carbide blades

4. Improper grinding methods will cause grinding stress and grinding cracks; Too much vibration of the teeth after grinding the PCBN milling cutter will cause excessive load on individual teeth and tool impact.

Countermeasures: (1) Intermittent grinding or diamond grinding wheel grinding; (2) Choose a soft wheel, wear it frequently, and keep it sharp; (3) Pay attention to the grinding quality and strictly control the vibration of the cutter teeth.

5. Improper cutting volume selection. If the volume is too loud, the machine will become stuffy; when cutting intermittently, the cutting speed is too high, the feed speed is too large, the margin is uneven, and the cutting depth is too small; for materials with a high tendency to work hardening, cutting high manganese steel is too slow.

Countermeasures: Reselect the cutting volume.

6. The bottom surface of the mechanical fixture groove is uneven or the blade is too long.

Countermeasures: (1) Trim the bottom surface of the groove; (2) Arrange the cutting fluid nozzle position reasonably; (3) Add a carbide gasket under the cutting edge of the carbide tool bar.

7. Excessive wear of the tool.

Countermeasures: Replace the tool or cutting edge in time.

8. Insufficient cutting fluid flow or incorrect filling method causes the blade to burst.

Countermeasures: (1) Increase the cutting fluid flow; (2) Arrange the cutting fluid nozzle position reasonably; (3) Use effective cooling methods such as spray cooling to improve the cooling effect.

9. Improper tool installation, such as: the tool is installed too high or too low; the face milling cutter uses asymmetric down milling, etc.

Countermeasures: Reinstall the tool.

10. The rigidity of the process system is too poor, resulting in excessive cutting vibration.

Countermeasures: (1) Increase the auxiliary support of the workpiece and improve the rigidity of the workpiece clamping; (2) Reduce the tool overhang; (3) Appropriately reduce the tool back angle; (4) Use other anti-vibration measures.

11. Unintentional operation, such as excessive movement when the tool cuts through the middle of the workpiece; the tool will stop immediately if it has not been withdrawn.

Ruida is a carbide tool manufacturer with ten years of professional experience, committed to providing high-performance cutting solutions. We offer a comprehensive product line, including tools, various types of inserts, router bits, and milling cutters to meet the needs of different industries. Our tools are made of solid tungsten carbide material through pressing and sintering to ensure excellent durability and cutting accuracy. All of our products are manufactured to exceed precise OEM standards

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