Above are a few of the thousands of microphotographs in the Machining Efficiencies library.
There are four distinctive types of wear patterns found on used broach tools. Eleven fairly distinctive types of wear patterns are found on disposable inserts, drills, reamers, taps, endmills and other tools. Each has a clear identification, cause and cure. Knowing the conditions of your operation, we can provide solutions to eliminate nagging problems or recommend changes to reduce your cost of manufacturing.
Each manufacturing process has its unique issues involving plant practices, knowledge levels, attention to detail, quality requirements and production criteria. Machining Efficiencies will help you improve your manufacturing condition and your profitability.
Here's an example that involved machining titanium.
Some background on the pictures in the Tool Wear sectionů Part metallurgy, tool material, tool coating, tool geometry and machining data (process set up) are woven into a dynamic chip-making system.Often, a subtle change in any one of these variables will dramatically affect your process.It's a matter of reading the tool wear pattern and adjusting the process properly to achieve your desired results which would probably be an improvement in tool life or microfinish.
The Tool Wear pictures are a review of tool wear patterns found on broach tools, disposable inserts, hobs, reamers, drills and taps.
There are 4 distinctive wear patterns on broach cutting tools made from M2, M3, CPMM4 tool steels.
There are 11 fairly distinctive wear patterns associated with carbide inserts. These patterns are found on other tools such as drills, reamers, taps, and endmills. 5. Built Up Edge phenomenon 6. Chipping Wear 7. Flaking 8. Spalling 9. Fracture 10. Flank / Nose / Face Wear 11. Notching Wear 12. Thermal Cracking (Shock, Fatigue) 13. Crater Wear (Diffusion Wear) 14. Deformation Wear 15. Cobalt Leaching
These microphotographs have been taken during 30 years of field experience investigating tool failure modes and effective remedies.