Printed from Kezuriba (kezuriba.net/en/troubles/flank-wear/)

Flank wear is rapid

Tool damage (wear and chipping) TurningMilling

Where it appears　Flank wear: an even band on the flank just below the cutting edge (controlled by its width VB)

Check first

Cutting speed is too high
Wear resistance of the grade is insufficient
Feed is too small, so the cutting edge rubs

Try first

Reduce the cutting speed
Increase the feed moderately
Use climb milling for end mills

?Likely causes

Cutting speed is too highAgreed by 2+ makers^{[1][2][3][4][5][6][7]}
Wear resistance of the grade is insufficientAgreed by 2+ makers^{[1][2][3][4][5][8]}
Feed is too small, so the cutting edge rubsAgreed by 2+ makers^{[2][5][3][6][9]}
Workpiece material is hard or contains hard inclusionsAgreed by 2+ makers^[1][5]
Up milling with an end millAgreed by 2+ makers^[7][6][9]
Tool runout causes uneven wear from tooth to toothAgreed by 2+ makers^[2][10][11]

✓Fixes

Cutting conditions

Reduce the cutting speedAgreed by 2+ makers^{[1][2][3][4][5][6][7]}
Increase the feed moderatelyAgreed by 2+ makers^{[2][5][3][6][9]}
Use climb milling for end millsAgreed by 2+ makers^[2][7][6][9]

Tool

Use a grade with high wear resistanceAgreed by 2+ makers^{[1][2][3][4][5][8]}
Use a larger clearance angle and a sharp edge geometryAgreed by 2+ makers^[4][8]

Setup

Keep runout to 0.02 mm or lessAgreed by 2+ makers^[2][12]

Coolant

Use wet cuttingAgreed by 2+ makers^[4][8]

↔Related problems

Large rake face wear (crater wear)Boundary wear (groove-like wear at the depth-of-cut line)Cutting edge chipping Fracture (large chipping or cracking)Workpiece material welds to the cutting edge Thermal cracks Plastic deformation of the cutting edge Flaking (peeling of the cutting edge surface)

📚Sources

Causes and fixes are summarized in our own words from cutting-tool makers’ troubleshooting guides and technical data. “Agreed by 2+ makers” means two or more makers say the same thing.

Sandvik Coromant — Troubleshooting in turning sandvik.coromant.com
Sandvik Coromant — Milling troubleshooting sandvik.coromant.com
Mitsubishi Materials — Advanced Turning: Troubleshooting mmc-carbide.com
Tungaloy — General Catalog 2023-2024 User's Guide L007: Turning troubleshooting (by damage type) tungaloy.com
Mitsubishi Materials — Advanced workpiece materials: Causes of tool damage mmc-carbide.com
OSG — Series No.8 End mills, Table 7.1 Troubleshooting, pp. 61-62 osg.co.jp
Mitsubishi Materials — End mills: troubleshooting mmc-carbide.com
Mitsubishi Materials — Turning troubleshooting mmc-carbide.com
Tungaloy tungaloy.com
Sandvik Coromant — Drilling wear and troubleshooting sandvik.coromant.com
OSG — Series No.24 Drilling, Table 7.4 Damage observation and Table 8.1 Troubleshooting, pp. 48-51 osg.co.jp
Mitsubishi Materials — Advanced Drilling: Cutting edge damage mmc-carbide.com