Flank wear primarily occurs on the relief face of a cutting tool. This type of wear is predominantly caused by the rubbing action between the tool and the newly machined surface during the cutting process.
Understanding Flank Wear
Flank wear is a common form of tool degradation observed in machining operations. It manifests as a worn-out area on the tool's relief (or clearance) face, which is the surface of the tool that is oriented away from the workpiece.
- Location: The specific area affected is the relief face of the tool. This face is designed to provide clearance between the tool and the workpiece to prevent rubbing, but wear still occurs here.
- Mechanism: The main cause attributed to flank wear is the continuous rubbing action of the tool against the surface that has just been machined. This friction generates heat and removes material from the tool's surface.
- Progression: Like other forms of tool wear, flank wear increases progressively as machining continues. As the wear land develops, it can alter the effective geometry of the tool, affecting surface finish and cutting forces.
Distinguishing Flank Wear from Crater Wear
While flank wear occurs on the relief face, it's important to differentiate it from other types of tool wear, such as crater wear, which affects a different part of the tool and is caused by different mechanisms.
| Wear Type | Location | Primary Cause/Effect |
|---|---|---|
| Flank Wear | Relief face of the tool | Rubbing action on the machined surface |
| Crater Wear | Rake face of the tool | Changes the chip-tool interface, affecting the cutting process due to hot chips flowing over the rake face |
Understanding where flank wear occurs is crucial for monitoring tool life, optimizing machining parameters, and selecting appropriate tool materials and coatings to mitigate tool degradation.
