There is no option to avoid replac­ing the tool some­day. How­ev­er, there are some engi­neer­ing tips you can take into account while think­ing about pro­long­ing the cut­ting tool life:

1. Choose the Right Cutting Tool for Your Specific Application

As the tech­nolo­gies are boom­ing today, so are the prod­uct offers in the cut­ting tool mar­ket. The strat­e­gy of your machin­ing process needs to be deter­mined care­ful­ly before choos­ing the right cut­ting tools. The cru­cial para­me­ters of your selec­tion are based on the machine lim­i­ta­tions, the mate­ri­als to be machined, and the cut­ting con­di­tions (depth of cut, feed, and speed cri­te­ria). Tak­ing into account all these fac­tors, our engi­neers can advise you on the best cut­ting tool mate­r­i­al (cubic boron nitride, poly­crys­talline dia­mond, etc.), appro­pri­ate grades, clear­ance angles, tool hold­ers and coolant. Choos­ing an appro­pri­ate cut­ting tool is a basic require­ment for the long tool life, high pro­duc­tiv­i­ty and well-pre­dict­ed cost per unit ratio.

2. Coping With the Heat Generated During the Cutting Process

Inten­sive, uncon­trolled heat­ing will result in the rapid decrease of the tool life and stim­u­late build-up-edge for­ma­tions. Defor­ma­tion is the final and obvi­ous sign of over­heat­ing. There is no way to avoid that heat in the process as it is a result of the ener­gy trans­for­ma­tion dur­ing the cut­ting process. How­ev­er, with the prop­er tem­per­a­ture reg­u­la­tion, it is pos­si­ble to min­i­mize the neg­a­tive con­se­quences of the heat. Under some (rare) cir­cum­stances the tools should be run dry, in all oth­er cas­es using coolant is required. It is impor­tant to choose the right type and amount of coolant: oil-based, syn­thet­ics or semi-syn­thet­ics, water, or com­pressed air.

3. Reasonable Cycle Time Versus Cost-Per-Second Race

Some­times man­u­fac­tur­ers incline to set aggres­sive speeds on their CNC machines because time is a crit­i­cal fac­tor in machin­ing. Push­ing the machines and cut­ting tools to the lim­it might result in a poor qual­i­ty of the final prod­uct and the tool fail­ure. At the same time, rea­son­ably imple­ment­ed high-speed machin­ing has a broad range of ben­e­fits for many appli­ca­tions. Thus, using the cut­ting tool at an opti­mal speed in each spe­cif­ic case is very impor­tant and will pro­vide the best results.

4. Paying Attention to the Different Kinds of Wear

Dur­ing reg­u­lar use, at some point, the cut­ting tool under­goes grad­ual wear. Dif­fer­ent types of wear require dif­fer­ent approach­es. Flank wear is a con­se­quence of long expo­sure to pres­sure. This kind of wear can be repaired, depend­ing on the degree of wear. As a tool man­u­fac­tur­er with years of expe­ri­ence, we can re-sharp­en or re-tip PCD, CBN and car­bide cut­ting tools for you. In most cas­es, repair­ing the tool is eco­nom­i­cal­ly reasonable.

Chip­ping of the edge is a type of cut­ting edge dam­age that, depend­ing on the size of the dam­age (microchip­ping is more favor­able), will lead to re-sharp­en­ing or re-tip­ping. Rapid chang­ing of the tem­per­a­ture can lead to ther­mal cracks and, lat­er, to frac­ture. Take a pre­emp­tive action, ask our engi­neers if we can pro­long the life of your cut­ting tools.