Category: Machining Tips

Introduction Built-up edge (BUE) is the accumulation of workpiece material on the cutting edge and rake face of the insert. When machining aluminum and other ductile, gummy materials, BUE is one of the most common and problematic wear mechanisms. The workpiece material welds to the insert under the high pressure and temperature at the chip-tool …

Built-Up Edge on Aluminum: Polished Insert and Speed StrategyRead More

Tungaloy vs ZCC-CT: Cost-Effective Alternatives for General Turning In an industry where cutting tool costs can represent 5-8% of total production expenses, finding reliable cost-effective insert brands is a strategic priority for CNC machine shops. Tungaloy, a Japanese manufacturer and member of the IMC Group, and ZCC-CT, a leading Chinese carbide manufacturer, both position themselves …

Chatter in Internal Boring: Bar Diameter vs Overhang SolutionsRead More

Introduction Plastic deformation of the cutting edge is a failure mode that occurs when the insert material itself softens and deforms under the combined effects of cutting forces and temperature. Unlike chipping or fracture, which are sudden and dramatic, plastic deformation is a gradual process where the cutting edge slowly rounds, flattens, or deforms away …

Plastic Deformation of Cutting Edge: Speed and Grade FixesRead More

Introduction Thermal cracking in carbide inserts is a failure mode that catches many machinists by surprise. The insert appears to be performing well, producing acceptable chips and maintaining dimensions, when suddenly the cutting edge spalls or fractures. Upon examination under magnification, a network of fine cracks is visible perpendicular to the cutting edge. These thermal …

Thermal Cracking in Inserts: Coolant Strategy to PreventRead More

Introduction Every machinist has examined a worn insert and wondered whether the wear pattern indicates normal operation or a process problem. Two of the most common wear types, crater wear and flank wear, are often misunderstood. While both are natural consequences of the cutting process, each type carries different diagnostic information about your machining parameters, …

Crater Wear vs Flank Wear: When Each Type Indicates a ProblemRead More

Introduction Notch wear at the depth-of-cut line (DCL) is one of the most common and destructive wear patterns encountered when machining stainless steel. This localized wear mechanism appears as a V-shaped groove that forms precisely where the cutting edge meets the workpiece surface. Unlike uniform flank wear, which is predictable and manageable, notch wear progresses …

Notch Wear at Depth of Cut: Causes and Prevention for StainlessRead More

Why Internal Threading Demands a Different Approach Internal threading on CNC lathes is one of the most demanding operations in turning. Unlike external threading, where the tool is fully visible and chip evacuation is straightforward, internal threading forces you to work inside a confined bore with limited visibility, restricted chip flow, and reduced tool rigidity. …

Internal Threading on CNC Lathes: Insert Selection and Toolpath StrategyRead More

Introduction Premature insert failure is one of the most costly and frustrating problems in CNC machining. When inserts break well before their expected tool life, you lose not only the cost of the insert itself but also valuable machine time, scrapped parts, and production schedule delays. Industry studies show that up to 40% of insert …

Why Your Inserts Break Prematurely: 12 Root Causes and SolutionsRead More

Complete reference guide for CNC cutting parameters: formulas for RPM, feed rate, and MRR with recommended cutting speeds for steel, stainless, aluminum, titanium, cast iron and more.