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Our cutters cracked during our grooving operation. This is the first time it has happened and it is only a few cutters cracking in the same position after only 10,000 feet.
We finished the follow up-checks on the cutters we produced for you (3158.0, 3158.1). Nothing appears out of the ordinary with the cutters and tested in our tolerances. The 3158 from the CPU12 that had lost a few pins and cracked in half tested for hardness in the 42-48 range. The ones that cracked in half tested no harder in the middle of the cutter than the the previous batch or the older batch.
We believe there is a problem with your machine, operator, surface, or set-up. The 3158 from the CPU10 (different site) showed none of the same issues as the ones used on the CPU12. The problems with the 3158s that were sent back from the CPU10 is it appears they were packed too tightly, and froze up on the shaft. Multiple cutters show wear on just one or two of the tips. None of these cutters appear to have lost any carbide; even on the excessively worn tips, the carbide remained intact.
Final analysis: the drum was set up too tightly, as nothing else appears to be wrong with the cutters.
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