Which cutting condition has the greatest effect on tool wear?

In machining and metal cutting processes, tool wear is a critical factor that affects product quality, efficiency, and cost. Tool wear refers to the gradual loss of material from the cutting edge of a tool, which can occur due to friction, heat, or chemical reactions with the workpiece material.

Several cutting conditions influence tool wear:

1. 
   

   Cutting speed – This is the velocity at which the cutting tool engages the workpiece. High cutting speeds increase friction and temperature at the tool-work interface. Excessive heat softens the cutting edge, causing rapid wear, chipping, or deformation. This makes cutting speed the most significant factor affecting tool life.

   
   


2. 
   

   Feed – The distance the tool advances per revolution or pass affects tool load and surface finish. While feed contributes to wear, its impact is smaller compared to cutting speed.

   
   


3. 
   

   Depth of cut – A larger depth increases the cutting force, which can also influence wear. However, compared to speed, its effect is less critical.

   
   

Tool wear can appear in different forms, such as:

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  Flank wear – on the tool’s side due to rubbing.

  
  


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  Crater wear – on the tool’s top surface due to high temperature.

  
  


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  Chipping or breakage – sudden fracture from mechanical stress.

  
  

By optimizing cutting conditions, especially controlling cutting speed, manufacturers can extend tool life, improve dimensional accuracy, and reduce production costs. Advanced techniques like coated tools, proper lubrication, and speed optimization are used in modern machining to minimize wear.

Analyzing the options:

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  A) Cutting speed – ✅ Correct. Most significant factor influencing wear.

  
  


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  B) Feed – Less impact than cutting speed.

  
  


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  C) Depth of cut – Influences wear but secondary to cutting speed.

  
  


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  D) None of the above – Incorrect.

  
  

In conclusion, controlling cutting speed is the key to reducing tool wear and maintaining machining efficiency.

✅ Correct Answer: A) Cutting speed