The Logic of Development

By Bhalchandra Chorghade, Editor, CNCTimes.com

In machining, a cutting tool is an element of a technological system that shapes a part by material removal. The system comprises a machine tool, a workholding fixture and a tool holding device. Shaping a part is performed by various machining processes that use different cutting strategies. The progress made in machining tools resulted in modern machines that enable combined and whole process operations; processes that were separated in the past. Moreover, advanced machine tool capabilities assure applying progressive machining strategies to achieve maximum performance.

The metalworking industry must deal with different engineering materials. Progress in material science and metallurgy not only brought in new exotic materials but also provided technologies to create materials with pre-defined properties. Producing components from such materials has significantly improved the working parameters of the parts, but machining has become more difficult. In many cases, the root of successful machining was connected only with cutting tool limitations.

A cutting tool, the smallest element of the technological system, connects the part directly and is the link between the machine and material. For realizing advantages of high-tech machine tools and productive machining strategies, the cutting tool must meet appropriate requirements. Finding a decent answer to these requirements to respond to ever-growing demands of modern metalworking is a base for new developments in the cutting tool field.

The metalworking industry has been through a rough time with the COVID-19 pandemic, which has affected the world economy and has inevitably led to a decline in economic indicators in the industry. Many bright prospects before the coronavirus were replaced by modest hopes, while on the other hand, this has been a time for deeper analysis of industrial trends, a look into tomorrow, forecasts, and future planning. Progress has not stopped.

Metalworking is at the door of serious changes, and the manufacturer should be ready to adopt them. The forthcoming changes cannot bypass cutting tool production - one of the more important links in the metalworking chain. Therefore, to have a clear understanding of the direction of industrial progress and the results of new requirements for the cutting tools of tomorrow is a cornerstone to success for a tool manufacturer. This is the key to new tool developments and the demand for a wide range of products.

There are different directions for the development of cutting tools. The "traditional" way is to make the tools stronger, more productive and cost-effective, a reflection on the natural requirement of the customer to a consumed product. Other directions of development are related to advanced manufacturing technologies that have deeply ingrained the metalworking industry; whereby available tooling solutions still leave a broad field for improvement.

The Course of Nature

The traditional direction of development considers improving tool performance by introducing innovative cutting geometry, advanced tool material grades, progressive tool body designs to ensure higher rigidity and durability, etc. It may seem that this direction has almost depleted its resources and does not promise true revolutionary changes, however, cutting tool manufacturers have managed to surprise the metalworking world with substantially new products that provide significant benefits despite the traditional approach to the product design.

An important success factor was the significant growth in scientific and technological levels of tool production, new achievements in powder metallurgy and coating technology, and the introduction of modern systems for inspection and quality control. The considerably increased capabilities of tool design itself, CAD/CAM systems, and 3D modeling, gave noticeable impetus to the realization of challenging innovative ideas.

Technological developments have evolved new machining methods which require tools to meet new stringent demands. These tools have the ability to cut hard metals while eliminating the need for grinding operations. In milling, these new age tools are able to contend with extremely high feeds per tooth (HFM) at high machining speeds (HSM) and are able to perform trochoidal milling with the use of high-pressure coolant (HPC).

The design of such tools differs from general-duty tools as they require specific features that characterize the above-mentioned methods and strategies.

Advancements in machine tool engineering have pushed the metalworking industry closer to living out a dream of every manufacturer, owning a complete one-setup production. Impressive capabilities of the latest multi-axis- and multi-tasking machine tools and hybrid manufacturing systems, which combine material removal and 3D printing technologies, give evidence of a quantum leap toward one-setup production. A driven-tool option features more and more turning centers expanding their capabilities. Understandably, this progress has built other requirements for cutting tools multifunctionality, tool life, and time-to-failure characteristics.

The attempts to find a cost-effective alternative to solid carbide tools gave a new impulse to designs with exchangeable carbide heads. Moreover, some of these designs even provided a substantial advantage for high repeatability of the head overhang with respect to the tool. As a result, there is no need for additional adjustment after replacing a worn head, which can be quickly changed without removing the tool from a machine spindle. The "no-setup" benefit opened a source for diminishing machine downtime, and in combination with distinct economic advantages, ensured promising prospects for the exchangeable solid-head concept as a direction of cutting tool development.

https://www.iscar.com/newarticles.aspx/countryid/1/newarticleid/10414

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