We attach great importance to customers' needs for product quality and rapid production.
We always insist that meeting customers' needs is to realize our value!
-
+86 133 9281 9446
+86 133 9281 9446
May. 23, 2025
Leo Lin.
I graduated from Jiangxi University of Science and Technology, majoring in Mechanical Manufacturing Automation.
CNC machining is an advanced machining process that is computer-controlled and produces precision parts to strict tolerances. When a part is produced, the cutting tool used to produce the part contributes to the workpiece machining accuracy, surface finish, and overall machining efficiency. If the proper tool choices for a manufacturing process are made, predictable and repeatable results will follow. In contrast, an incorrect tool choice will lead to defects and increased costs.
Making the proper tool options whenever CNC machining is performed will support lower tool wear, better part quality, and longer cutting life of the tool. Uncontrolled tool wear will lead to dimensional non-conformances, poor surface finishes, and unplanned downtime of machines, leading to potentially higher scrap rates and costs to operate. Controlled wear will provide a consistent machining process, leading to lower costs.
Tool wear is a major consideration in CNC machining; tool wear affects the dimensional accuracy of manufactured workpieces and the costs of manufacturing the product. Tool wear occurs when cutting tools apply force to the workpiece to sever material from the part. Tool wear occurs when friction and heat cause wear to the cutting edge of the cutting tools.
This wear introduces poor surface finish, incorrect shapes and dimensions to manufactured parts, and consequently, increased costs of machining. Managing tool wear provides operators the ability to maintain efficiencies in machining, reduce waste in production, and limit scrap parts.
Tool wear occurs whenever the cutting edge of the tool is worn from repeated machining of workpieces, so wear distorts the shape of the cutting edge of the tool, and machining a part with a distorted or worn cutting edge will yield less accurate cuts. Tool wear occurs in CNC machining operations, i.e., milling and turning operations; even a small amount of wear can affect the accuracy and precision of the manufactured workpiece.
In situations where cutting tools are subject to unmonitored, uncontrolled wear throughout the cutting operation, the workshop will produce a scrap part more often, and operators will be forced to replace cutting tools sooner than expected. This leads to increased operational expenses, which also reduces production rates.
● Tool material determines life and heat resistance. Carbide tools are able to operate at high speeds and on harder materials. Ceramic tools are used at extreme heat and can be brittle. High-speed steel (HSS) is good for softer materials and tends to be the least expensive.
● Workpiece material impacts the choice of tools. For example, aluminum needs sharp, polished edges to reduce buildup. On the other hand, titanium and stainless steel will require solid and heat-resistant tools.
● Flute count influences the finish and chip removal capacity. More flutes will yield a smoother finish, but there will be less room for chips. Fewer flutes will perform better for roughing.
● Tool coatings improve performance. Titanium Nitride (TiN) coatings improve wear resistance. Diamond coatings excel in hard abrasive materials, such as composites.
Choose tools that match the operation. Roughing tools remove material at the fastest rate but typically have a rough surface finish. Finishing tools create the part and often hold tighter tolerances.
Always check the manufacturer’s specifications for cutting speeds and feed rates. Running the tool too fast will cause overheating, and too slow will reduce efficiency.
Tool geometry is important to consider. Variable helix will improve performance in deep cuts by reducing vibration. Tools with a corner radius will provide a stronger edge for a longer life of the tool.
End mills range from roughing end mills to ball nose end mills and can be used to mill slots, pockets and contours. Ball nose end mills will give a smooth 3D shape as well.
Twist drills can make standard holes in metals, plastics, and composites. Spot drills create exact hole starting locations.
Boring bars refine internal diameter to very tight tolerances in a high-accuracy bore. Adjustable boring heads allow for precise diameter adjustment.
Face mills maximize the removal of material from large flat surfaces. Indexable inserts extend the life of a cutting too,l thereby reducing replacement costs.
Thread mills accurately create internal and external threads while avoiding the risks attached to broken Taps.
Tool wear management while operating CNC machining centers is necessary to assure efficiency and limit downtime. Advances in monitoring technology and predictive methods help manufacturers to obtain the most life out of a cutting tool and ensure that the same level of consistency exists in part quality. The information in this section discusses available real-time tool wear monitoring options, wear mitigation methods, and best practices in preventive maintenance.
TMAC and DTect-IT are advanced systems that utilize acoustic emission sensors to identify and measure tool wear while running. These systems continuously measure the natural high-frequency sound waves produced during the cutting process and reflect changes in frequency based on tool wear progression, thereby recognizing and preventing possible catastrophic tool failure and subsequently unexpected stoppage of equipment. Systems operational on CNC machines often link functionality directly with the CNC controller, allowing for automatic adjustments or notifications should cutter wear exceed predetermined limits.
Vibration analysis refers to measuring vibrations induced by dulling or damaging tools. Listening for increased vibration allows the operator to remove a dulling effect and take action before the part quality is affected by the cascading effect on tool life if operation is continued. Force monitoring systems measure resistance to cutting; a small but progressive increase in cutting resistance (force) leads to flank wear, while increased resistance only indicates problems when they occur as spikes. Optical inspection via machine vision can enable monitoring of the condition of a tool during an automatic tool change or even against recommended patterns, and baseline measures of edge conditions.
Predictive analytics combine historical data of tool life with real-time sensor data to identify tool life remaining. If, within limits provided by the manufacturer, predictive analytics can be used to even accommodate uncontrolled wear situations, which could lead to reduced tool life and product variability based on type of part that is being produced. Machine learning algorithms result from continuously improved calculations with inputs of cutting forces, temperatures, and all computable vibration data, providing the tools necessary to establish when it may not be prudent to continue using the cutting tool without risking product quality. Many new CNC machines now feature predictive built-in functions that maintain records of a tool, and from that record generate a maintenance schedule of parts, so they can be managed in a predictive landscape.
Correct cutting parameters vastly influence wear rates, for hard materials where the feed rate can be reduced by drafting from several to 10-15%, doubling the life of the tool. For machines using emulsion coolants, failure to incorporate filtration techniques and maintenance practices effectively compromises the ability of the coolant to provide cooling and lubrication consistently, which cannot only lead to thermal cracking but also other failures. For extreme temperatures, minimum quantity lubrication (MQL) functions like KoolTool to apply only what is directly functional on the cutting zone, without dumping excessive amounts of fluid. CAM Software even creates better toolpaths to limit wear.
Check for flank wear using any method you can, including a digital imaging system or microscope, to monitor if the wear is subtle or gradual. All tools should be maintained in a low-humidity environment with a protective coat to prevent corrosion. Any operator training program should include a comprehensive visual understanding of wear patterns, including thermal discoloration, as sustained fatigue, and direction of wear which is often deposit patterns in micro-chipping. Implementing a tool presetting program reduces the variability of tool condition, so not only functionality, but also inferior performance can be eliminated during a tool change. For shops that run Scripts, Autonomous tools can measure key dimensions set before key operations.
Determining the correct tools related to material and machining operations is the key ingredient for effective machining. When combined with real-time monitoring and predictive maintenance, a more systematic approach to wear management is available. Correct use of the tool and coolant, proper application of all parameters, including speed and feed, and systematic coolant management practices will promote productive tool life while improving dimensional accuracy and consistency in produced components.
Manufacturers that implement the above consistently can change their approach to tool maintenance and management from a reactive process to a systematic, proactive process. Sensor technologies, data analysis, and preventative maintenance allow for ongoing improvements in quality and profitability, whereas small incremental improvements across the entire process, from CNC machining tool selection, monitoring the tool, and maintaining the tool, will achieve observable improvements in overall equipment effectiveness (OEE).
We attach great importance to customers' needs for product quality and rapid production.
We always insist that meeting customers' needs is to realize our value!
