Tool wear on machining of difficult-to-machine materials: a review

Difficult-to-machine materials are characterized by high hardness, strength, and anisotropy. During machining, tools can suffer from adhesion, abrasion, material detachment, and high cutting temperatures. These factors result in severe adhesive wear, abrasive wear, oxidative wear, and diffusion wear. Intense tool wear leads to more burrs, delamination, chipping, and dimensional errors in the parts. It significantly increases production costs and reduces machining efficiency. Therefore, further research into tool wear is of great importance. This paper reviews the characterization and monitoring of tool wear, the morphology and mechanism of wear, and measures for improving wear, with a focus on tool wear in the machining of difficult-to-machine materials. Through a comprehensive review of existing research findings, this work offers a perspective on the investigation of tool wear, providing an effective guide for future research. And it is of great significance to improve tool life and cutting quality.