Mold Cutting Tools

Getting coolant to the cutting edge is critical for any manufacturing application. It helps in cooling the cutting zone, provides very needed lubrication, and can assist in breaking a chip. Many times, external lines are used to splash coolant near the work zone. Long Chips can easily interfere with this delivery method, possibly knocking the lines out of the way. Additionally, when tools need to be changed or indexed coolant lines might be moved for better access to the tool. Then when the line is put back it is never the same as it previously was. Often times there is a give-and-take methodology used to cover areas being machined with this coolant, so all tools get some cooling, but none of them get ideal cooling. A coolant-through tool allows pinpoint accuracy with a specific direction of coolant pointed exactly at the cutting zone.

Source: Q&A: Trends in Cutting Tool Application

There’s been a big change is the ability to drill small-diameter holes very deep and do this in a production atmosphere. Part of this comes from the drilling machines being able to reach the necessary speeds and holders that provide superior clamping and runout. The other part comes from tools designed specifically for this drilling application.

On a coolant-through tool, material could be added in areas that may need additional strength, allowing for the intersecting coolant ports to be drilled accordingly.

Source: Q&A: Trends in Cutting Tool Application

Machines and tools seem to have a back-and-forth dance in terms of which is leading. Coatings continue to evolve, with more layers, and different material being used. This is something all tool manufactures are playing with on some level. The changes in coating technology is somewhat more limited, and not as many are playing in this arena. One process that comes to mind is “HiPIMS,” or high-power impulse magnetron sputtering. This process uses microsecond timing of extreme-power pulses. This allows the metal to ionize to nano size particles to be deposited on the tools. This process allows for greater adhesion and coating hardness, while maintaining great lubricity. Additionally, this process has greatly reduced compressive stresses. This reduction allows for smaller edge preps to be used, thus resulting in sharper tools.

Developments in polycrystalline diamond (PCD) and cubic boron nitride (CBN) have allowed these materials to improve in ways that make them more versatile and cost-effective. Meanwhile, the machining speed and tool life of these tools continue to take machining processes to levels of performance where carbide cannot go.

Through long tool life and fast cutting parameters, the tools increase machine capacity by reducing the frequency of tool replacements and allowing machines to make parts at a greater rate. Meanwhile, the tooling increasingly figures into expert solutions tailored to more demanding applications in various industries.

Source: The New Rules of Cutting Tools - Rule #3: Diamond Shouldn't Be Rare

Polycrystalline diamond (PCD), cubic boron nitride (CBN), ceramic, high-speed steel (HHS), cemented carbide or cermet.

Sources: What's Happening With Cutting Tools

Why Binderless CBN Inserts Turn Titanium Faster