Which of the following processes is most likely to cause tool failure?

Tool failure can arise from various factors in metal cutting processes, and identifying the most likely causes is crucial for maintaining tool longevity and performance.

Tool chatter refers to a vibrational phenomenon occurring during machining, where the cutting tool and workpiece oscillate. This can lead to inconsistent cutting, increased wear, and ultimately, significant damage to the cutting edge of the tool. Over time, the cumulative effects of tool chatter can result in premature tool failure.

Overheating occurs when excessive heat is generated during cutting operations, primarily due to friction and inadequate heat dissipation. High temperatures can lead to thermal deformation and accelerated wear of the cutting tool. In severe cases, overheating can weaken the tool material, leading to failure.

Inadequate lubrication is another critical factor. Proper lubrication during machining helps reduce friction and dissipate heat. Insufficient lubrication can cause surfaces to bind, increasing wear, tool degradation, and the likelihood of chip welding. This not only accelerates wear but can also lead to catastrophic tool breakage.

Because each of these factors contributes significantly to tool wear and the potential for failure, acknowledging that all three processes can be detrimental establishes a comprehensive understanding of tool management during metal cutting operations. Consequently, indicating that all of these issues can lead to tool failure is