“Accelerated Carbide Tool Wear Failure during Machining of Hot Work Hardened Tool Steel: A Case Study”, Int. J. Structural Integrity, 2015, Vol. 6(2), 290-299.
G. Pantazopoulos, A. Toulfatzis, A. Vazdirvanidis, A. Rikos
Abstract
Purpose – The purpose of this paper is to outline and document the failure root
cause of a carbide cutting tool during machining of a hardened tool steel under
automatic machining conditions.
Design/methodology/approach – Optical metallography and SEM/energy dispersive
spectroscopy analysis, together with optical profilometry were employed for failure
investigation. The use of an alternative cutting tool andmodification ofmachining
conditions are proposed as a failure preventive action.
Findings – Severe abrasive wear and adhesion of machining chips are observed in the
flank zone, causing blunting of the cutting edge. The revision of cutting conditions,
together with the use CBN-based tool insert leads to an overall improvement of the
stability of the process and tool lifetime.
Originality/value – This paper places emphasis on a failure analysis case history following a structured approach in industrial machining problem solving, highlighting
suggestions for process improvement.