What is tool failure?

State of the tool when it ceases to function satisfactory.

Wear-loss of material due to rubbing action between two surfaces

results in change in the desired geometry.

Sture Hogmark, Uppsala University, The ngstrm Laboratory, Sweden

Mikael Olsson, Dalarna University, Sweden

Criterion of tool failure

1. Total tool destruction/ breakdown
The cutting tool is unable to cut .

It produces highly burnished surface of work, nose of tool

completely worn-out.
2. Temperature failure

The tool get overheated and cutting edge get soften and stop
functioning.
This is due to when temperature of machining zone exceed hot
hardness temperature.

Criterion of tool failure

3. Increased feed
Due to excessive feed, flank wear takes place.

4. Increased in power consumption

Due to tool failure, cutting force will increase results in more
power consumption

5. Poor surface finish

Occurrence of sudden change in surface finish of work surface.
6. Increased noise level
Sudden change in the cutting noise level.
7. Chipping of tool

8. Formation of crack

Types of tool failure

Tool failure may be classified as
1. Temperature failure- This can be due to either

a. Plastic deformation of cutting edge due to high temperature

b. Cracking at the cutting edge due to thermal stress
2. Chipping of the edge or fracture due to mechanical impact

3.Built up edge
4.Chemical decomposition
5. Gradual microscopic wear

Fatigue and fracture:

Macroscopic fracture of the whole tool can occur. More common is localized chippings of
the tool edge

(a) Edge fracture (b) edge chippings due to local overloading and
fatigue of hob teeth.
Wear mechanisms of HSS cutting tools Sture Hogmark, Uppsala University, The
ngstrm Laboratory, SwedenMikael Olsson, Dalarna University, Sweden

Types of tool failure

Tool failure may be classified as
1. Temperature failure- This can be due to either

a. Plastic deformation of cutting edge due to high temperature

As cutting speed increases-temperature at tool tip increases
As feed increases temperature and cutting force will increase.

Apart from speed and feed, the deformation is depends upon depth
of cut and tool geometry.
Use of coolant greatly reduced the deformation.
b. Cracking at the cutting edge due to thermal stress

Types of tool failure

Tool failure may be classified as
2. Chipping of the edge or fracture due to mechanical impact

Occurs during engagement and disengagement with work.

Chipping is not depends upon speed, feed and depth of cut.
3. Built up edge(BUE)

BUE protect rake face when it

is stable and increases tool life.
But when it is unstable , large
force is exerted by chip on
BUE

which

breakdown of

results

BUE

in

which

Tool wear
Tool wear may be defined as loss of weight of tool.
Effects of tool wear
1. Increased cutting force
2. Poor surface finish
3. Reduced dimensional accuracy

4. Vibration
5. Tool failure
6. Damage workpiece geometry

Types of cutting tool wear

1.Adhesion wear.
2.Abrasive wear.
3.Diffusion wear.
4.Fatigue.
5.Microchipping.
6.Plastic deformation/temperature failure
2002 John Wiley & Sons, Inc. M. P. Groover, Fundamentals of Modern Manufacturing 2/e

1. Adhesion Wear:

fragments of the workpiece get welded to the tool surface at high

temperatures; eventually, they break off, tearing small parts of the tool
with them.
2. Abrasion:
hard particles, microscopic variations on the bottom surface of the

chips rub against the tool surface.

Abrasive wear dominates the flank and crater wear

3. Diffusion wear:

at high temperatures, atoms from tool diffuse across to the chip; the
rate of diffusion increases exponentially with temperature; this reduces
the fracture strength of the crystals.
e.g. machining of Cast iron by diamond tool

Sture Hogmark, Uppsala University, The ngstrm Laboratory,

Sweden
Mikael Olsson, Dalarna University, Sweden

4.Plastic deformation:

Sometimes, the HSS tool edge is loaded beyond its yield strength
and deforms by large-scale plastic deformation.
resulting in edge blunting.

Wear mechanisms of HSS cutting tools Sture Hogmark, Uppsala University, The
ngstrm Laboratory, SwedenMikael Olsson, Dalarna University, Sweden

7. Gradual wear occurs at two locations on a tool:

a. Crater wear occurs on top rake face at some distance from
cutting edge.

b. Flank wear occurs on flank (side of tool)

The worn region at the flank is called wear land

7. Gradual wear occurs at two locations on a tool:

a. Crater wear occurs on top rake face at some distance from
cutting edge.

Crater reduces the strength of tool and may lead tool failure.

Caused due to adhesion, diffusion and friction.

Both crater and flank wear takes place when feed is greater than

0.15mm/re at low or moderate speed.

Crater wear is defined by ratio Hc.

7. Gradual wear occurs at two locations on a tool:

a. Flank wear occurs on flank (side of tool)
The worn region at the flank is called wear land

Wear land width is measured by accurately with a Brinell

microscope.
This increases the no of cutting forces, spoils surface finish etc.

7. Gradual wear occurs at two locations on a tool:

a. Flank wear occurs on flank (side of tool)

Flank wear:
Is normally caused by:
Sliding of tool over work piece; causes adhesion, adhesive wear.
Temperature; famous Taylors equation (FW Taylor, 1907)

VT c
n

V=cutting speed, T= time that it takes to develop flank wear, n=exponent depend on
cutting condition, c=constant
Tool life vs. cutting speed is plotted on a log-log graph. We can directly obtain n from it:
Range of n
High speed steel: 0.08 to 0.2
Carbides: 0.2 to 0.5

Ceramic: 0.5 to 0.7

Temperature:
Since temperature effect physical properties experiments have been done to prove it.

Tool life curves:

New Equation:

VT d f C
w

d=depth of cut, f=feed (mm/rev)

T C1/ nV 1/ n d x / n f y / n