Built-up edge forms

?Likely causes

• Cutting temperature (cutting speed) is lowAgreed by 2+ makers^{[1][2][3][4][5][6]}
• Sticky, soft materials (low-carbon steel, stainless steel, aluminum)Agreed by 2+ makers^[1][2][7][8]
• Negative geometry or small rake angleAgreed by 2+ makers^[1][2][3][9]
• High affinity between the tool grade and the workpiece materialAgreed by 2+ makers^[4][6][5]
• Feed is smallOne maker^[2]
• Coating is thickOne maker^[1]
• Insufficient lubrication from the cutting fluid (low oil content in water-soluble fluid)Agreed by 2+ makers^{[3][10][11][12]}

✓Fixes

Cutting conditions

• Increase the cutting speed to raise the cutting temperatureAgreed by 2+ makers^{[1][2][4][6][5][9]}
• Increase the feedAgreed by 2+ makers^[2][6][5]

Tool

• Use a positive geometry with a large rake angle and a sharp edge (small honing)Agreed by 2+ makers^[1][2][4][6]
• Use a grade with low affinity (cermet, PVD coating)Agreed by 2+ makers^{[1][2][4][6][9]}

Coolant

• Use a highly lubricating fluid (non-water-soluble, or water-soluble with high oil content)Agreed by 2+ makers^{[4][6][5][3][12]}
• In milling, turning off the cutting fluid to raise the cutting temperature is also an optionOne maker^[2]

Where sources differ: In drilling, raise the speed for built-up edge at the center and lower the speed for built-up edge at the periphery (Sandvik).

▦Notes by material

• Aluminum alloy: Welds easily, and built-up edge degrades accuracy and surface finish^[8][2]
• Stainless steel: High affinity with the tool grade, so welding and built-up edge occur easily^[13][2]

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