Failure analysis of two cold-working cutting tools. Case studies

Abstract

The study examines the dramatic drop in the efficiency of a cutting tool. The specific tool is part of machine used for cutting envelopes of paper for medical products packaging. Two similar pieces, selected after breaking down in service, were examined in depth. Historical data was collected. The tool temperature range during operation and the material hardness were measured. The fracture surfaces as well as the surrounding areas were carefully inspected. Chemical analysis was performed in order to identify the tool and coating materials. Results showed that components were made of different steels: D2 and Vanadis 6. The coating material also differs. Samples were selected and prepared for optical and electron microscopy. The condition of the cutting edges and the heat-treated microstructure were considered. Thickness, quality and homogeneity of the coatings were also inspected. Both tools failed by fatigue mode under different conditions. The fracture mechanism and its principal causes are discussed. The reasons of failure for both cutting tools are examined and compared. Poor designs associated with improper handling have led to the components breakage. Appropriate recommendations are given in order to eliminate similar situations and to improve the cutting performance.