Common Causes of Insert Chipping and How to Prevent It

Insert chipping is a common issue that can affect the performance and longevity of various tools, including drills, taps, and end mills. Understanding the causes of insert chipping and implementing preventive measures can significantly extend the life of your tools and maintain their accuracy. Below are some of the most common causes of insert chipping and practical ways to prevent them.

1. Incorrect Material Selection

Using an insert that is not suitable for the material being machined is a primary cause of chipping. Different materials require different grades of inserts to prevent chipping. For instance, a high-speed steel (HSS) insert may chip easily when used on hard materials like stainless steel or titanium. To prevent chipping, ensure that you select the correct insert grade for Cermet inserts the material you are working with.

2. Inadequate Coolant Use

Insufficient or improper use of coolant can lead to insert chipping. Coolant not only cools the tool but also flushes away chips and debris from the cutting area. Without adequate coolant, the insert can overheat, leading to chipping. Always use the recommended coolant type and volume for your application to prevent chipping.

3. Excessive Speed or Feed Rate

Operating the tool at an excessive speed or feed rate can cause insert chipping. Each material and tool has an optimal speed and feed rate that should be followed to ensure the longest tool life. If the speed or feed rate is too high, the insert may overheat and chip. Always consult the tool manufacturer’s recommendations for the best performance.

4. Poor Tool Mounting

Improperly mounted tools can lead to insert chipping. If the tool is not securely mounted, it may vibrate or wander during operation, causing the insert to chip. Ensure that the tool is properly installed and secured in the machine to prevent chipping.

5. Insufficient Clamping Force

Insufficient clamping force can cause the tool to deflect or chatter, leading to insert chipping. It is important to apply the correct amount of clamping force to maintain the tool’s stability during operation. Too little force can result in chatter, while too much force can damage the tool holder or machine.

6. Incorrect Cutting Conditions

Operating the tool under incorrect cutting conditions, such as incorrect depth of cut or over-restrictive corner radii, can also lead to insert chipping. Always follow the recommended cutting conditions for your tool and material to prevent chipping.

7. Preventive Measures

Here are some general preventive measures to help reduce the risk of insert chipping:

• Use the correct insert grade for the material and application.
• Always use the recommended coolant type and volume.
• Operate the tool within the optimal speed and feed rate range.
• Ensure proper tool mounting and secure the tool in the machine.
• Apply the correct amount of clamping force to maintain tool stability.
• Follow the recommended cutting conditions for your tool and material.

By understanding the causes of insert chipping and taking the necessary precautions, you can significantly extend the life of your tools and maintain their APMT Insert accuracy. Always consult the tool manufacturer’s guidelines for the best results and tool performance.