What is the result of tool wear that causes small fragments to break off from the cutting edge?

Chipping is the result of tool wear that leads to small fragments breaking off from the cutting edge. This phenomenon typically occurs due to the repeated mechanical stresses and impacts that the cutting edge encounters during machining. As the tool interacts with the workpiece material, localized stress can exceed the material strength of the tool at certain points, resulting in tiny pieces or chips fracturing off. This type of wear can significantly affect tool life and performance, as even minor chipping can change the geometry of the cutting edge and lead to further wear or tool failure.

Crater wear, on the other hand, relates to the gradual wear that occurs in the form of a concave depression on the tool’s rake face, primarily due to the high temperatures and sliding contact with the material being cut. Built-up edge involves the formation of a layer of workpiece material that adheres to the cutting edge, which is a separate wear mechanism. Tool rupture indicates a complete failure of the tool due to excessive stresses, rather than the gradual loss of small fragments seen in chipping. Each of these wear types has distinct characteristics and causes, highlighting the importance of understanding tool wear mechanisms in manufacturing processes.