Determinants of flank wear: Which factors significantly influence flank wear on a single-point cutting tool during turning?

Introduction / Context:
Flank wear is the progressive loss of material from the tool’s relief (flank) faces due to rubbing against the newly generated surface. It affects dimensional accuracy and surface finish and is commonly used as a criterion for tool life end-point (e.g., VB land limit). Recognizing the key drivers of flank wear helps in optimizing cutting parameters and tool selection.

Given Data / Assumptions:

• Continuous turning with a single-point tool.
• Normal ranges of speed, feed, and depth; no severe chatter.
• Work materials may contain varying amounts of hard phases (e.g., carbides).

Concept / Approach:
Flank wear arises from abrasion, adhesion, and mild diffusion at the tool–work interface on the relief faces. The dominant influences are relative hardness at temperature, abrasive hard inclusions in the work, and work-hardened surface layers that increase rubbing stress. Thus, material properties of both tool and work, and the degree of strain hardening, directly affect wear rate.

Step-by-Step Solution:

Verification / Alternative check:
Empirical tool-life tests (Taylor plots) and metallography of worn tools consistently show higher wear rates when machining abrasive cast irons or heavily cold-worked materials; improved results follow from higher hot-hardness tools and appropriate coatings/coolant.

Why Other Options Are Wrong:
Each individual factor has a clear mechanistic link to wear; choosing any single factor ignores the multi-causal reality. “None of these” is plainly incorrect.

Common Pitfalls:
Blaming only cutting speed; overlooking the role of abrasive microstructure; failing to account for work hardening near the surface (common in stainless steels and nickel alloys).

Final Answer:
all of these