Tool wear at low cutting speeds is predominantly influenced by rounding-off of the cutting point and subsequently loses sharpness. With the increase of depth of cut, the swept area is considerably increased and that causes to decrease the tool life significantly. For a particular cutting tool and workpiece material combination, the tool wear progression may depend exclusively on the cutting conditions, principally the cutting speed, v, and the undeformed chip thickness, t, and a combination of different wear mechanism. Tool wear is a progressive failure mechanism, generally comprising the predominant wear mode, dependent upon the cutting conditions, workpiece and tooling material, and the tool insert geometry. The tool wear mechanism during metal cutting and its corresponding effects have been thoroughly described by Li ( 2). However, all of them come up with tool wear, tear, and breakdown. The effect on the tool might be mechanical, chemical, thermal, and abrasive. The entire phenomena have their particular effect on the process and also on the state of the tool. The different happenings during machining damage the tool condition and disturb the process stability. A tool may fail in different ways like progressive flank wear, crater wear, notch wear, built-up-edge (BUE), frittering, thermal crack, fracture, plastic deformation, and breakage. are the fundamental occurrences inseparably involved with machining which damage the effectiveness of cutting tools.

The tool wear, tool fracture, chip formation, chip breakage, chip removal, tool breakdown, etc. Choudhury, in Comprehensive Materials Processing, 2014 13.22.2.1 Unavoidable Occurrences

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