Trouble shooting PCBN
Troubleshooting – PCBN
Problem
Cause
Suggested action(s)
Flank wear
• Increase cutting speed • Increase feed rate • Increase depth of cut • Check cutting tool centre height • Check the ferrite content
Not correct edge temperature
Crater wear
• Decrease cutting speed • Decrease feed rate
• Reduce chamfer angle • Use E edge preparation • Use coated insert • Use coolant (only in continuous cut)
Not correct edge temperature
Notch wear
• Increase cutting speed • Decrease feed rate • Increase insert approach angle (preferably round inserts) • Vary the depth of cut • Use inserts with chamfered cutting edges • Use inserts with chamfered cutting edges • Increase system rigidity • For interrupted cuts, chamfer the tool entry/exit slots and holes • Vary the cutting speed to eliminate vibrations
Not correct edge temperature Too high cutting forces
Edge chipping
Too high cutting forces
Edge flaking (continuous cut)
• Increase cutting speed • Reduce feed rate • Use chamfered and honed cutting edges
Too high cutting forces
• Check cutting tool center height • Reduce insert approach angle
Edge flaking (interrupted cut)
• Do not use coolant • Use chamfered and honed cutting edges • Reduce feed rate • Increase cutting speed
Too high cutting forces
• Check cutting tool centre height • Reduce insert approach angle
Edge breakage
• Reduce depth of cut • Reduce cutting speed • Increase nose radius
Too high cutting forces
• Use chamfered and honed inserts • Check cutting tool center height
Insert breakage
• Check insert seating • Check insert shim and insert clamp • Check cutting tool centre height
Too high cutting forces
903
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