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Book Chapter

Tool Wear and Tool Life

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By L. Alden Kendall
Book: Machining
Series: ASM Handbook
Volume: 16
Publisher: ASM International
Published: 01 January 1989
DOI: 10.31399/asm.hb.v16.a0002120
EISBN: 978-1-62708-188-7
... Abstract Cutting tool wear is a production management problem for manufacturing industries. It occurs along the cutting edge and on adjacent surfaces. This article describes steady-state wear mechanisms, tertiary wear mechanisms, and tool replacement. It provides information on tool failure...
Abstract
Cutting tool wear is a production management problem for manufacturing industries. It occurs along the cutting edge and on adjacent surfaces. This article describes steady-state wear mechanisms, tertiary wear mechanisms, and tool replacement. It provides information on tool failure and its consequences. The article details the modeling of tool wear by using the Taylor's tool life equation. The article concludes with information on the requirements of a successful tool life testing program: the test plan objective, designing the test, conducting the test, analyzing the results, and applying the results.
View PDF for content titled, <span class="search-highlight">Tool</span> <span class="search-highlight">Wear</span> and <span class="search-highlight">Tool</span> Life
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Effect of tellurium on tool wear. Tool wear, as measured by part growth, in...

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in Machinability of Steels > Properties and Selection: Irons, Steels, and High-Performance Alloys
Published: 01 January 1990
Fig. 13 Effect of tellurium on tool wear. Tool wear, as measured by part growth, in multiple-operation machined parts of quenched and tempered 4142 and a similar grade with tellurium. Cutting speed was 0.5 m/s (99 sfm). Source: Ref 11 More
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Tool wear mechanisms. (a) Crater wear on a cemented carbide tool produced d...

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in Surface Engineering of Carbide, Cermet, and Ceramic Cutting Tools > Surface Engineering
Published: 01 January 1994
Fig. 2 Tool wear mechanisms. (a) Crater wear on a cemented carbide tool produced during the machining of plain carbon steel. (b) Abrasive wear on the flank face of a cemented carbide tool produced during the machining of gray cast iron. (c) Builtup edge produced during low-speed machining More
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Typical tool wear when broaching with a carbide cutting tool at 45 m/min (1...

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in Machining of Aluminum and Aluminum Alloys > Machining
Published: 01 January 1989
Fig. 17 Typical tool wear when broaching with a carbide cutting tool at 45 m/min (150 sfm). Source: Ref 2 More
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(a) Original and updated mesh geometry in cutting tool. (b) Tool wear curve...

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in Modeling and Simulation of Machining > Metals Process Simulation
Published: 01 November 2010
Fig. 16 (a) Original and updated mesh geometry in cutting tool. (b) Tool wear curve family, with simulated tool curve superimposed. Courtesy of The Ohio State University ERC/NSM. Source: Ref 39 More
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Tool wear measurement setup for milling

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in Fundamentals of Tribology in Machining > Friction, Lubrication, and Wear Technology
Published: 31 December 2017
Fig. 16 Tool wear measurement setup for milling More
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Geometry-update-scheme (GUS) for tool wear simulation. Reprinted with permi...

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in Lubrication and Wear in Sheet Forming > Friction, Lubrication, and Wear Technology
Published: 31 December 2017
Fig. 12 Geometry-update-scheme (GUS) for tool wear simulation. Reprinted with permission from Elsevier. Source: Ref 26 More
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Relationship between tool wear and punch-die clearance obtained experimenta...

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in Lubrication and Wear in Sheet Forming > Friction, Lubrication, and Wear Technology
Published: 31 December 2017
Fig. 15 Relationship between tool wear and punch-die clearance obtained experimentally when blanking Docol 1400 DP, 1 mm thick by Högman. Source: Ref 27 More
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Typical cutting tool wear when broaching with a tungsten carbide cutting to...

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in Machining of Aluminum Alloys > Aluminum Science and Technology
Published: 30 November 2018
Fig. 16 Typical cutting tool wear when broaching with a tungsten carbide cutting tool at 45 m/min (150 ft/min). Source: Ref 7 More
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Cutting tool wear of cemented tungsten carbide cutting tools when turning a...

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in Machining of Aluminum Alloys > Aluminum Science and Technology
Published: 30 November 2018
Fig. 18 Cutting tool wear of cemented tungsten carbide cutting tools when turning aluminum metal-matrix composites at 100 m/min (328 ft/min) cutting speed. Nose radius: 0.8 mm (0.03 in.) More
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Cutting tool wear of polycrystalline diamond (PCD) cutting tools when turni...

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in Machining of Aluminum Alloys > Aluminum Science and Technology
Published: 30 November 2018
Fig. 19 Cutting tool wear of polycrystalline diamond (PCD) cutting tools when turning aluminum metal-matrix composites at a cutting speed of 500 m/min (1640 ft/min). Nose radius: 0.8 mm (0.03 in.) More
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Comparison of tool wear for austenitic stainless steels with (S32100) and w...

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in Wrought Stainless Steels > Properties and Selection: Irons, Steels, and High-Performance Alloys
Published: 01 January 1990
Fig. 38 Comparison of tool wear for austenitic stainless steels with (S32100) and without (S30400) titanium carbide inclusions. Source: Ref 86 More
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Comparison of tool wear for austenitic stainless steels with (S32100) and w...

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in Machining of Stainless Steels > Machining
Published: 01 January 1989
Fig. 24 Comparison of tool wear for austenitic stainless steels with (S32100) and without (S30400) titanium carbide inclusions. Source: Ref 50 More
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Tool wear curves for the single-tooth milling of alloy 390 engine blocks (w...

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in Machining of Aluminum and Aluminum Alloys > Machining
Published: 01 January 1989
Fig. 29 Tool wear curves for the single-tooth milling of alloy 390 engine blocks (wet) at 0.30 mm/rev (0.012 in./rev). A, carbide, 150 m/min (492 sfm); B, diamond, 1500 m/min (4920 sfm); C, diamond, 150 m/min (492 sfm). Source: Ref 2 More
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Tool wear versus feed rate at four surface speeds in drilling 120 holes in ...

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in Machining of Metal-Matrix Composites and Honeycomb Structures > Machining
Published: 01 January 1989
Fig. 7 Tool wear versus feed rate at four surface speeds in drilling 120 holes in a Fiber FP aluminum MMC using solid carbide tools. Source: Ref 7 More
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Tool wear versus speed after drilling 120 and 180 holes in a Fiber FP alumi...

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in Machining of Metal-Matrix Composites and Honeycomb Structures > Machining
Published: 01 January 1989
Fig. 8 Tool wear versus speed after drilling 120 and 180 holes in a Fiber FP aluminum MMC. Tool wear increases after 45 m/min (150 sfm). Source: Ref 7 More
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Tool wear versus feed rate in turning a Fiber FP aluminum MMC using an unco...

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in Machining of Metal-Matrix Composites and Honeycomb Structures > Machining
Published: 01 January 1989
Fig. 9 Tool wear versus feed rate in turning a Fiber FP aluminum MMC using an uncoated C-2 grade insert. Note how the wear rate progress was significantly less when feed rates reached ≧0.320 mm/rev (0.0126 in./rev). Source: Ref 7 More
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Tool wear curves for different cutting velocities

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in Tool Wear and Tool Life > Machining
Published: 01 January 1989
Fig. 9 Tool wear curves for different cutting velocities More
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Schematic illustrating typical cutting tool wear. Source: Ref 21

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in Machining of Carbon and Alloy Steels > Machining
Published: 01 January 1989
Fig. 20 Schematic illustrating typical cutting tool wear. Source: Ref 21 More
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Average high-speed steel tool wear while machining UNS G11460 steel bars at...

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in Machining of Carbon and Alloy Steels > Machining
Published: 01 January 1989
Fig. 22 Average high-speed steel tool wear while machining UNS G11460 steel bars at 40 m/min (130 sfm). Depth of cut was 2 mm (0.08 in.), feed rate was 0.1 mm/rev (0.004 in./rev), and rake angle (α) was 20°. Source: Ref 22 More