There are mainly 2 types failure mode for the PCD tools

1) Crater wear

The crater is commonly found in high-speed machining of iron-based or titanium-based alloys, which is a thermal or chemical problem in which the insert dissolves into the 

workpiece's chips.The combination of diffusion wear and abrasive wear causes crater. In processing substrates and titanium-based alloys, the heat in the workpiece's chips 

dissolves and diffuses the cemented carbide components into the chips, creating a "crater" on the top of the insert. The crater will eventually increase enough to cause 

micro-collapse, deformation of the flank, and possibly even rapid flank wear.

2) Built-up edge

When the pieces of the workpiece are welded to the cutting edge by thermocompression bonding, a built-up edge occurs, which is caused by chemical affinity, high pressure 

and high temperature in the cutting zone. The built-up edge eventually falls off and sometimes falls off with the insert fragments, resulting in micro-disintegration and rapid flank

wear.

This failure mechanism is common in viscous materials, low speed, high temperature alloys, stainless steel and non-ferrous materials, as well as threading and drilling. The 

built-up edge can be identified by anomalous changes in the size or surface roughness of the workpiece and the shiny material that appears on the top or flank of the cutting edge.

The built-up edge can be controlled by increasing the cutting speed and feed rate, using a nitride (TiN) plating insert,, using a proper coolant (such as increasing the concentration), 

and selecting a geometry with reduced force or A blade that smoothes the surface.