The belief that dull inserts must be thrown away has been reinforced by failed efforts to regrind used inserts to gain additional useful life before the insert must be discarded. The most ambitious of the regrinding attempts to reclaim dulled inserts, frequently referred to as "downsizing", is provided by North American Carbide, Inc. of Broken Arrow, Okla. In this process, the "dulled"/used insert is reground using specially adapted grinding machinery so that an insert that is virtually identical to the original, only slightly smaller, is obtained. Unfortunately, the success of this process has been rather limited as the reduction in overall size of the insert results in the same problems as would be encountered by using the machine of Schott et al., i.e. reduction of the size of the inscribed circle resulting in difficulty in accurately clamping the insert within the tool holder. Many companies initially embraced this concept, recognizing the significant financial advantage of being able to increase the life span of an insert. However, the difficulties encountered with clamping the inserts to fit accurately within the tool holder once it had been refurbished quickly diminished the enthusiasm for the approach. Consequently, the belief that cutting inserts are only capable of a one-time use and then must be thrown away continues to prevail after all these years.
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