In this article, we will be revealing the top 6 common material deformations that newbies produce and how you can avoid it.

1. Normal Flank Wear

Normal Flank Wear is a type of material deformation that can either be caused by low coolant
pressure and extremely high speed that is being used during the cutting process. Since your material
is heat resistant, it does not necessarily require that you put the machine at the highest speed.
Selecting a more wear resistant cutting tool grade can also help.

2. Cratering

Every machinist wants to produce a smooth and nice finish on the material, cratering is one of
the common material deformations that produces rough and uneven cut. One of the possible reasons
could be using too high of a speed during the cutting process.
Remember that excessive temperature can cause rough finish on the material. If after slowing
down the cutting speed, if it still it produces cratering deformation problem, you should select a more
wear resistant grade material cutting tool.

3. Plastic Deformation

Another deformation caused by extremely high cutting temperature is plastic deformation. Aside
from using slower pace of cutting speed. The plastic material’s grade also matters, if it’s not hard enough it
cannot withstand the whole machining process. You should slow down the feed rate to produce better
cutting finish.

4. Notching

This material deformation can be possibly solved by varying the depth of the cut of the material.
Make sure that your material is made from a high quality mill too. When making a depth cut, use a slower
speed for a smoother and nicer finish.

5. Thermal Cracking

When the surface has too high of a temperature, this can cause cracking on the material. You can
can try eliminating the use of coolant during interruptions. The grade of the material also determines
the result of the finish. If ever the material continues to product thermal cracking after performing
the possible remedies, change your chip former and/or the the material for your project.

6. Edge Fracture

This deformation can be possibly solved by reducing the depth of the cut set for the material .
Edge fracture occurs when there’s too much temperature applied and if the material’s grade is too
low.

These are the 6 common Material Deformations that most newbies produce when they just get
into machining. These are learning curves that every aspiring machinist should learn about, but if you
can avoid and take note of these lessons in advance, then you will find learning machining more
fulfilling.