AiVibeBuilt-Up Edge (BUE)
Built-up edge is workpiece material that welds onto the cutting edge under heat and pressure, forming an unstable false edge that grows and breaks away, harming surface finish, dimensions and tool life.
When conditions favour adhesion, layers of workpiece material pressure-weld onto the rake face near the cutting edge. This deposit changes the effective tool geometry and periodically breaks away, sometimes taking fragments of tool material or coating with it. Built-up edge is most common at relatively low cutting speeds and with ductile, adhesive materials such as aluminium alloys, low-carbon steels and stainless steels.
BUE is a frequent cause of torn or smeared surface finish, inconsistent dimensions and edge chipping in turning, milling, drilling and tapping. Identifying it, by inspecting the edge for adhered material, guides corrective action before parts are scrapped.
Typical remedies include increasing cutting speed to raise the cutting temperature above the adhesion range, using sharper and more positive edge geometries, polished rake faces or suitable coatings, and improving lubrication with appropriate cutting fluid. Tool suppliers' application guidance should be followed for specific materials, because the best remedy depends on the material, tool grade and operation.
Key points
- Workpiece material welds onto the edge and forms an unstable false edge
- Common at low cutting speeds in aluminium, mild steel and stainless steel
- Causes poor finish, dimensional variation and edge chipping
- Remedies include higher speed, sharper geometry, coatings and lubrication
Where AiVibe comes in
AiVibe designs and manufactures the AiAmbA AI Factory: edge devices plus AI agents that let people talk to CNC, PLC and robot controllers in plain language. Agents only propose changes, and a trained operator confirms each one.