Tool wear occurs when high impact tools such as drills or saws become dull due to high temperatures and normal use. Flank, edge, crater, and accumulated wear are common types that can affect cutting efficiency and require replacement.
Tool wear occurs when some tools used for high impact work such as cutting or drilling begin to wear, changing the cutting profile or overall effectiveness of that tool. Many different types of tool wear are possible, and wear will vary based on the type of tool, the type of work being done with that tool, and how hot the tool is at the peak of its operation. High temperatures often accelerate the wear process of the tool, especially if the tool is used improperly or is used very often.
Flank tool wear is perhaps the most common type of tool wear and occurs with normal use. It occurs when the part of the tool that comes into contact with the surface to be cut or drilled begins to wear, not necessarily becoming dull, but rather dull. Drill bits and saw blades can experience flank wear after a significant amount of normal use, and sufficient flank wear will indicate when the tool or part of the tool needs to be replaced.
Edge wear is a type of tool wear that occurs on drill bits and can make the drill bit ineffective. It occurs when cutting edges wear out after high temperatures and high speeds cause the tool to dull at the cutting edge. It most commonly occurs at the tip of the drill bit, but can also extend along the cutting channels of the drill bit, especially if particularly high speeds are used. This type of tool wear makes the drilling process exceptionally difficult and can even prevent the drill bit from cutting properly. At high speeds, an edge-worn drill bit can heat both the drill bit and the workpiece, leading to burning or even breaking of the bit.
Another common type of tool wear is crater wear, where the cutting edge of any tool gets pitted or metal chips break off the cutting surface. While this type of wear can cause a slight change in the cutting process, it is usually not a significant problem unless the drill bit or other cutting tool begins to cut through too much or not enough material, thus altering the shape or the cutting efficiency. Accumulated tool wear can also occur; this happens when the material on the cut surface heats up and then transforms, building up in a weathered cut surface. This happens most often at high speeds and high heat and can significantly alter the cutting process.
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