I. Storage Management: Prevent Cutting Edge Damage

Environmental Control:

• Rust formation on cemented carbide inserts due to moisture;
• Chip adhesion on coated insert edges (dust accumulates on coatings, causing abrasion).

Protection & Isolation:

• Unused indexable inserts: Retain original packaging or store in pad-protected cases to prevent edge chipping/collision.
• Form blades (e.g., thread/grooving blades): Store separately to avoid profile deformation from mechanical stress.

Categorization & Labeling:

• Model (e.g., TNMG160408),
• Material (cemented carbide/ceramic/CBN),
• Edge condition (unused/used/indexable).
  Label wear levels to avoid misusing worn-out edges.

II. Pre-Use: Critical Checks Before Clamping

Cleaning & Degreasing:

• Clean tool holder clamping surfaces and insert pockets with specialized cleaners (alcohol, tool cleaner) to remove oil (oil films reduce clamping force, causing vibration/chipping).
• For coated inserts: Avoid direct contact with sweaty hands; clean fingerprints from edges immediately (sweat corrodes coatings).

Visual Inspection:

• Inspect edges under strong side illumination for:
  
  • Chipping, cracks, or local coating delamination (delaminated areas accelerate wear).
• For indexable inserts: Verify uniform nose radius.
• For form blades (e.g., thread blades): Check thread/profile integrity.

III. During Machining: Control Cutting Conditions to Reduce Damage

Parameter Matching:

• Follow insert specifications for spindle speed, feed rate, and depth of cut:
  
  • Example: Cemented carbide on steel → feed rates > 0.3mm/r cause overload; ceramic inserts require ≥200m/min for efficiency.
• For interrupted cutting (e.g., slots, steps): Reduce parameters by 20–30% to avoid impact chipping.

Cooling & Chip Evacuation:

• Prioritize high-pressure internal coolant (especially for deep-hole boring); ensure flow ≥15L/min to flush chips (buildup scratches edges).
• Coolant choices:
  
  • Kerosene for aluminum (anti-sticking);
  • Extreme-pressure cutting oil for stainless steel/titanium (lubrication);
  • Dry cutting for cast iron roughing (avoids graphite adhesion).

Vibration Monitoring:

• If unusual noise or vibration marks appear: Adjust feed rate or spindle speed (e.g., 3000rpm → 3500rpm to break resonance).
• For thin-walled parts: Use small nose radius inserts (e.g., R0.2mm) – inherently vibration-resistant.

IV. Post-Use: Cleaning + Protection for Extended Life

Timely Cleaning:

• Clean edges and chip breakers with a soft brush + neutral cleaner (avoid coating damage). For stubborn chips: Ultrasonic cleaning (≤5 minutes to prevent delamination).
• For cemented carbide inserts with built-up edges (BUE): Gently scrape with a bamboo strip (metal tools scratch edges).

Rust Prevention & Storage:

• After cleaning, air-dry:
  
  • Coated inserts: No oil (affects clamping precision);
  • Cemented carbide inserts: Apply a thin anti-rust oil layer.
• For indexable inserts: Mark worn surfaces post-indexing; collect worn inserts centrally (avoid mix-ups).

Wear Evaluation:

• Measure flank wear land width (e.g., ≥0.3mm for cemented carbide on steel → index/replace).
• For form blades (e.g., thread blades): Check thread/profile wear; discard if precision exceeds tolerance.

Key Technical Notes:

• Indexable inserts: Focus on preventing edge collision during storage.
• Coated inserts: Minimize human contact to avoid coating corrosion.
• Form blades: Prioritize profile integrity during storage and inspection.