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The insert that lasted 3x longer after I checked the wiper angle
Ran a job last month with a 45 degree lead angle on some 4140 and the inserts were burning out every 90 parts. I was about to blame the material or the coolant mix, then I grabbed the insert catalog from the drawer and actually read the chipformer specs. Turns out the wiper geometry was mismatched for my feed rate, I ran 0.012 per tooth but the insert wanted between 0.006 and 0.008. Swapped to a different insert with a tighter wiper radius and got 280 parts before I had to flip it. New inserts are a bit pricier but the cost per part dropped by 40%. Anyone else ever ignore the recommended feed range and pay for it in tool life?
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andrew_baker91d ago
Swarf color is the tell nobody talks about. If it's coming off silver or light straw you're fine, but the second it turns blue or dark purple you're already cooking the edge, regardless of what the chart says. Sounds like you caught it before it got real expensive, some guys burn through half a box of inserts before they even look at the chip.
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juliaa6513h ago
Blue chips at 0.012 feed just mean you're hogging metal, 90 parts is plenty for roughing.
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