Shops may employ reaming as a machining procedure to complete bores. Reaming has advantages over other procedures, like a single-point boring, in terms of speed, tool life, and surface finish quality.

Decoding the Art of Reaming

Reaming is the process of completing a bore by using a cutter to remove a little quantity of material. It combines cold working and cutting materials. Reamers are made to manage size and polish the surface but not to provide true position. Because a reamer usually follows the pre-reamed bore, its condition and location are crucial. 

The uneven flute spacing results in its high performance, setting them apart from regular reaming tools. In comparison to typical reamers with equal flute spacing, this is touted to produce precisely round holes and a greater surface quality. These multi-edge reamers, according to the manufacturer, may also be operated at higher rates and feeds while still producing excellent holes with tight dimensional tolerance and high-quality surface finishes.

 Its reamers can be tipped with polycrystalline diamond, cermet, or carbide (PCD). Modern thin-film PVD coatings can enhance performance, particularly in materials like stainless steel, grey cast iron, and a variety of high-temperature superalloys. 

These reaming tools, according to the manufacturer, have three main advantages: 

  • Greater feed and speed rates.

When opposed to single-point boring, high-performance reamers’ many cutting edges enable faster feed rates and shorter cycle times. When compared to a single insert in a single-point boring tool, high-performance reamers have four to 16 teeth; the increase in feed rate can be four to 16 times faster. 

Since a bore needs to be the right size and finish, single-point boring is employed, however because there is only one cutting edge working, it is naturally slower. 

  • Quick setup. 

Setting the reamer is an easy process with high-performance reaming because the initial bore is a nice bore. The tool has been ground to the proper diameter, so there is no need to change it. Reaming is also a secure and reliable technique that doesn’t need as much altering as single-point boring. 

  • Slashing waste. 

When working with very expensive materials, minimising scrap is especially crucial. For instance, manufacturers frequently make fewer parts made of expensive materials like titanium, Inconel, and other such materials in the aircraft industry. Using a high-performance reamer can help these manufacturers maintain consistent hole sizes over the course of the tool’s life and dramatically reduce scrap rates. 

Understanding the Solid and Expandable Reamers 

There are two main types of high-performance reamers: expandable and solid (nonexpandable). An expandable reamer allows the operator the option to expand the reamer within the tolerance area of the bore to prolong tool life because reamers do wear out with use. Targeted at the average bore diameter is an expanding reamer. 

Up until the point where the surface finish is no longer acceptable due to wear, the expansion can be repeated. 

The reamer can now be retipped to its original position. 

In comparison to traditional reamers with equal flute spacing, unequal flute spacing is stated to produce precisely round holes and a greater surface quality. 

A solid reamer’s diameter should be within tolerance by two thirds. 

Given that this kind of reamer cannot be enlarged, this is done to allow for greater wear. 

The reamer can also be retipped once it has reached the end of its useful life in terms of size or surface polish. 

Expandable and solid reamers can be aimed practically anywhere within the diameter tolerance field to suit particular application requirements or client requests. Tolerance for hole diameter and desired surface finish are two factors to take into account when choosing between expandable and nonexpandable reamers. Expandable reamers are better suited for tight-tolerance bores with relatively harsh surface finish callouts because they can be expanded to extend tool life. Because the surface finish typically deviates from specification before the diameter, a bore with a higher surface finish callout is better suited for a nonexpandable reamer. 

Reason for reaming

  • To correctly finish drilled holes with suitable surface quality and size, reaming is used. 
  • It has the benefit of allowing for the consistent production of more holes of high quality. 
  • Reaming is necessary, with the precise diameter needed. 
  • It needs to have an appropriate edge profile. 
  • Where a well-sharpened surface is required, it is necessary. 
  • A precise pre-machined hole is required for reaming. 

Benefits of Reaming 

  • Production rates range from 10 to 500 items per hour. 
  • Inexpensive in terms of equipment and tools. 
  • Low-cost finishing also required cleaning and deburring. 
  • The surface finish is improved by reducing the feed rate. 
  • Reaming is done under ideal circumstances at one-third of the drilling speed and two-thirds of the drilling feed rate. 
  • Center-drilled, drilled, bored, and reamed to finished size holes are the most exact. 
  • Surface roughness measurements range from 0.4 to 6.3 m Ra. 

Reaming and boring are comparable types of processes, albeit they differ in certain ways. Yet, both processes serve the same function and involve a similar kind of effort. Therefore they are both beneficial to manufacturing businesses.

Looking for the highest-quality reamers, shop from Accusharp!



The size of the global Carbide Tools market is anticipated to increase from USD 10.39 billion in 2021 to USD 15.47 billion in 2029, at a CAGR of 5.5% over the forecast period, according to Fortune Business Insights. Cutting tools have truly grown significantly in importance with the rise in demand brought on by global industrialization and the requirement for an operational and well-functioning economy when it comes to heavy industrial activities and extraordinary production. 

The convergence of Industry 4.0 with the potential for extensive commerce and adoption on the cutting tool market has also been one of the industry’s biggest trends. Things appear good for the players in the manufacturing of cutting tools, especially with the suite of Industrial Internet of Things solutions designed to make it easier for industrialists to organize for Industry 4.0. 

Also, the use of new-age technology is pushing industrialists to use modern tools in order to take advantage of the expanding worldwide needs. The industry is always looking for technological answers to the problems it has been facing for years.

The industry’s use of cutting-edge techniques and technology indicates that India is actively strengthening its positioning as a hub for global manufacturing while simultaneously setting ambitious infrastructure goals. 

The cutting tool industry, whose demand comes from a diverse range of industries, is eager to embrace the chance. Adoptive as they are, Indian manufacturers are continually seeking ways to use innovative technology to address the obstacles that come with delivering the anticipated demands. 

  • Constantly Increasing Demand

The industry is well positioned to take advantage of opportunities in a growing economy, thanks to the cross-sectoral demand for improved cutting tools. Demand for innovative cutting tools will continue to increase in the upcoming years, driven by industries as broad as general engineering, transportation, energy, and the aerospace market. This is also because the effective use of cutting tools affects manufacturing costs as a whole. 

  • Expanding Obstacles

Each application—boring, drilling, or deep hole drilling—presents a unique difficulty in terms of choosing the right cutting tool. The most popular cutting tool, the drill, which comes in different shapes for different sorts of applications, is seeing a significant transition in terms of technology adoption due to the numerous issues it poses. Drilling, deep hole drilling, and boring are three of the most complicated machining operations, and they have all seen the development of several solutions to the problems they provide. 

One of the trickiest machining procedures is hole creation. At the same time, developments in the field of hole-making have a significant impact on the production of extremely complex objects. On the shop floor, issues like changing drills, which increases operation time, and setting boring tools, which introduces errors and backlashes, are daily occurrences. 

Among the most significant difficulties that drill operators have are chip evacuation, chip jamming, chips getting out of control, and inappropriate chip evacuation. Other warning signs include vibration and a lack of coolant. 

  • Technology Advancement

Indian enterprises are implementing more sophisticated production techniques than those in certain other developed nations. Hole Making for India asserts that manufacturers are adopting technology more quickly than ever before. The market’s rising NPS (New Product Sales) ratio, which indicates that “the rate at which customers and producers are adopting change in the technologies is increasing,” proves the thesis for India.

Businesses must provide clients with a compelling value distinction in a cutthroat market. Adopting developing trends in cutting tools with innovation, streamlined manufacturing processes, sophisticated surface treatments and grades help producers to generate that competitive value distinction. 

The sector does, however, provide a wide range of end-users. Therefore the adoption rate of new technologies naturally fluctuates depending on the end markets a manufacturer targets. Customers who produce intricate, crucial parts with tight tolerances adopt new technology more quickly than those who produce less important parts. 

Similarly to this, clients who produce components in batches would have a different adoption rate than those who produce in large quantities. 

Aside from such unique variations, “cutting tools will lead the charge” as new technologies continue to impact the future of the manufacturing business. 

  • Inserts for cutting tools 

The cutting tool inserts market is another one that will experience good expansion. Because cutting tool inserts have a short lifespan of only fifteen minutes, the majority of revenues in the market for cutting tool inserts originate from replacement. The market for cutting tool inserts is predicted to develop incrementally over the coming years as a result of the ongoing requirement for replacement through new units. 

  • Slowed-down boring-bar technology 

Vibration reduction in turning by damped boring bar technology is another significant cutting-tool advancement that should raise some red flags. Cutting tools made with this technique have improved hole quality and reduced vibration when performing extended-reach internal turning operations. 

Thus, practically all major tool manufacturers offer some form of damped boring bar technology for this frequently problematic application. Moreover, manufacturers have developed instruments with Bluetooth-capable sensors and a smartphone app to actively check dull conditions. 

  • 3D Printing

Cutting-tool goliaths are pursuing another cutting-edge tool-making approach to advance the evolution in this market, using a technology that can expand the number of manufacturers familiar with 3D Printing. Businesses are experiencing remarkable success in the autonomous vehicle manufacturing industry, reducing the milling time on a composite shuttle chassis massively. Moreover, setup times were shortened because of the quick-change Capto head. 

The Closing Statement

Today, a significant factor limiting the growth of the cutting tools market is the environmental issues and the health of the cutting tools. Cutting fluids are heavily reliant on suppliers and machine tool manufacturers to regulate the high temperature, reduce wear and rust, offer lubricity, and provide chip evacuation in cutting tools. Even yet, the machine operators’ health may be vulnerable as a result of the fluid exposure. With ongoing and significant infusions of R&D funding, traditional alternatives are emerging with improvements in industrial safety gear for operators.



End mills are made with a specific purpose in mind, and each tip shape provides a different clearance route for a range of applications. The project, the type of material that needs to be cut, and the desired surface finish all play a role in determining which end mill to use. By using the incorrect cutting tool, one could easily ruin a workpiece and have to throw away an entire batch. It can end up costing the company a lot of money in addition to a great deal of time. Hence, the art of choosing the right end mill is very critical!

Remember the fact that each tool has a distinct geometry that is essential to the final result of the cutwork procedure. Before starting the tool selection process, it is advised to ask to consider few important factors listed below:

Following these and making the extra effort to choose the best tool will shorten cycle times, prolong tool life, and result in higher-quality products. 

–The Material Being Cut

Your end-mill confusion will be much reduced if you are aware of the qualities of the material you are working with. Each material has a unique set of mechanical characteristics that give it distinctive qualities when being machined. 


For instance, machining plastic materials requires a different approach than machining steels, as well as various tool geometries. It will help to increase tool performance and longevity to select a tool whose geometries are designed to take advantage of those particular properties. 

Operational Aspect

One or more operations may be necessary for an application. 

Typical machining processes include: 

Old-fashioned Roughing 




High-Efficiency Plunge 


A machinist will be able to determine the tooling that will be required by comprehending the operation(s) required for the work. For instance, choosing a Helical Solution would be appropriate if the task involves conventional roughing and slotting. It would be preferable to use a chip breaker rougher to remove more material than a finisher with numerous flutes. 

Tool Dimensions Required

The following step is to ensure that the end mill chooses the appropriate dimensions for the project after describing the material being worked with, the operation(s), and the necessary number of flutes. 

Key factors include things like cutter diameter, cut length, reach, and profile. 

-Mill End Length 

It is adequately important to choose the length of the mill required. Choose the shortest end mill length that still allows for cutting because the stability of the tool is substantially improved by selecting the smallest length. This will lessen the tool’s propensity to chatter while enabling more aggressive feeds and speeds. 

Mill End Coatings 

Coatings are beneficial for minimizing friction and shielding the carbide from the heat produced during cutting. Some materials respond better to certain coatings. Again, the simplest method to make sure you are applying the right coating is to pay attention to the manufacturer’s instructions. 

-End Mill Components 

High-speed steel (HSS) and carbide are two of the materials most frequently utilized to make end mills. HSS is suitable for one-off or very short-run production as well as older, slower, or less stiff machinery. It will operate more slowly but cost less, is less fragile, and is more forgiving of adverse environments. 

When higher speeds, fewer tool changes, and increased productivity are needed, carbide is chosen in CNC machine tools. In many applications, the longer tool life and faster cycle times easily justify the greater cost. 

— Number of Flutes

Choosing the right flute count for an end mill is one of the most important factors to take into account. This choice is significantly influenced by both the material and the application. So, be careful!

Life and Durability

Cheaper isn’t always better. It’s essential to invest in the correct machinery that can handle the volume of work if you have a high rate of production and a lot of workload. 

The time and money you spend on wasted materials, scrap, wasted tool purchases, and increased wear and tear on your CNC machines result from choosing cheap or inadequate tooling. 

Whatever the task, Accusharp Cutting Tools offer you a broad selection of end mills made to give you a competitive advantage. Also, we can help you choose the perfect one based on your application. So, reach out to us!



There are many materials all around us that need to be cut or shaped into different shapes or sizes. For instance, while working in your shed, you could need to cut through a wooden or plastic covering. While in the automotive cutting application, you would need something way more precise and complex! 

You have a variety of choices when it comes to cutting instruments/tools. To begin with, cutting through soft materials like wood or plastic is simple because they are both materials that cut easily. Some materials demand cutting tools that are tougher and more powerful. Carbide-cutting tools are useful in the second scenario – where proficiency is the key!

Carbide Cutting Tools – Introduction

One of the toughest instruments on the market is carbide-cutting equipment. They are produced using tungsten carbide cemented. When it comes to cutting hard items, there are many different cutting tools available on the market for various tasks, but carbide cutting tools promise to deliver one of the most impressive results!

For both commercial and industrial use, carbide-cutting tools are offered in a range of sizes. These tools have a long lifespan and may maintain their cutting-edge toughness. 

Also, they shorten the machine’s cycle time when they are utilized with it. This is made possible by how effective these tools are at faster speeds. They also provide superb surface polish. 

Because the carbide chip on the tool’s surface is resistant to wear and tear, carbide tools are also great in terms of longevity. As a result, the carbide tools will last longer, reducing the likelihood that you will need to replace them anytime soon. 

The functions of carbide-cutting tools go beyond simple cutting. They can also be used as face mills and for turning. 

When it comes to cutting highly abrasive materials, these tools are the industry standard. The solid carbide’s hardness makes handling abrasive material considerably simpler. 

High-Speed Steel vs. Carbide Tools

Compared to high-speed steel, carbide tools are tougher. They are superior to tools made of high-speed steel in other ways as well, though. Moreover, better cutting speeds and longer tool life are provided by carbide cutting tools. 

Moreover, high-speed steel reaches its red hardness maximum at about 650 degrees Celsius, while carbide steel’s red hardness ranges from 800 to 1000 degrees Celsius. 

Micro-Grade Cut with Carbide Tools

Steel that has been hardened cannot be cut with the typical micro-grain carbide grade. This is because hardened steel is far more powerful than carbide. Thus, hardened steel is cut using dry machining. There are, however, some carbide tool varieties that can cut through hardened steel. 

With carbide-cutting tools constructed with ultrafine micro grain or nanograin carbide, one can cut through hardened steel as well. These carbide variations offer stronger heat resistance in addition to being denser. These variations are particularly good at cutting through-hardened steel when both of these characteristics are together. 

Tungsten or Carbide 

Compared to steel and, in many circumstances, titanium, carbide is harder. To begin with, it has a Vickers number of roughly 2,600 and a Mohs hardness rating of 9 or 9.5. Moreover, it possesses Young’s modulus between 530 and 700 GPa. 

Chemically speaking, carbide is a compound composed of tungsten and carbon atoms in an equal ratio. It naturally comes as a powder in various shapes that you can press out of a grey substance. 

Concluding Note

Cutting tools made of carbide have been around for a while. They have gradually begun to replace older tools made of diverse materials. Tools made of carbide perform superbly in practically every application. Since they produce the most precise and cleanest cuts, they are one of the most often used categories of cutting instruments. 

This kind of cutting tool is well renowned for getting the job done, whether you’re cutting plastic, wood, steel, hardened steel, or even titanium. The cleaner cuts will produce an overall product that is finer and cleaner and will help reduce kickbacks. 

While costly, carbide tools are more durable than other cutting tools and can persist during a lengthy production cycle. They are a great investment because of their fantastic cutting speed and improved heat resistance. 

Some of the most highly-priced carbide tools variations, such as Ultrafine Micrograin Carbide and Nanograin Carbide, are even more heat-resistant and easily handle harder materials, like hardened steel. So, choose high-quality carbide tools for your precision-demanding cutting jobs. Choose Accusharp tools!



Standard tooling is by its very nature general and purpose-made, while custom tools should achieve a number of objectives above and beyond those of standard tooling. A custom tool should perform better where regular tools are effective since it was designed specifically for the task at hand. 

If a business uses bespoke tools, that equipment ought to enhance machining outcomes by offering the following benefits: 

  • Shorten the duration of the cut. 

Where surface finishes are less important, some elements can be merged into a form and created in a single pass. 

  • Minimize the time spent on cutting. 

Some procedures let you combine two or more tools. By doing this, the number of tool changes that waste time can be decreased. Moreover, it can expand the machine’s ability to store tools. 

  • Lengthen the total tool life. 

It is possible to optimize coolant ports that do not need to be adjusted. By doing this, operator error is decreased, and the coolant flow is always directed. 

  • Increase effectiveness. 

The cutting of inserts includes edge finishing and coating that are tailored to the material being machined. This enables an insert to operate to its full capacity. 

  • Cut back on part costs. 

Usually, the ultimate objective is to lower the cost per component. 

This is easily accomplished with custom tools that decrease cutting and non-cutting time, but there are still a few other enhancements to take into account. 

  • Boost the process’s dependability. 

If an operator’s mistake is an issue, it could be required to design a special tool with various inserts that are only compatible with the tool’s own pocket. The possibility of mixing up tools that are so similar always exists, so the only way to tell them apart is by utilizing a loop to verify the part identification number is reduced by using different types (single edge, triangular, and dog-bone forms). 

  • Easy handling

It shouldn’t be hard to swap out a worn insert or index for a new cutting edge. An operator needs to be able to make a minor adjustment and press cycle start after a fresh edge has been clamped into position. It shouldn’t be necessary to use shims or have unnecessarily sophisticated application-specific tooling. 

  • Boost precision. 

To preserve precise dimensions between two or more features that depend on one another’s placement, form tools can be ground. The accuracy of the insert is checked in some establishments. Only one dimension on the finished component needs to be checked by the operator if the distance between features is within tolerance. We already know the other dimensions. 

  • Boost energy efficiency. 

A properly calibrated free-cutting tool will require less horsepower to remove the material with careful planning. Combo tools use less compressed air and fewer tool changes. Although air is free, maintaining or replacing the machinery that compresses it is expensive. 

Creating effective custom tools 

Existing criteria have a direct impact on tool design. Thus the tool manufacturer must first take into account the machine and other process characteristics in order to comprehend the customer’s application. While designing a custom tool, assumptions shouldn’t be based solely on component drawings because they only provide a partial picture of the situation. 

It is important to think about the kind of machine tool that will be used to run the parts. The kind of raw material has an impact on the custom tool design, whether the blanks are forgings, bars, or slugs. 

Evaluation might even recommend an alternative strategy to the intended machine type. A component that appears to be the ideal choice for lathes could be acquired as slugs and produced in bulk on a vertical mill. 

Another factor is the amount of power available. Oversized form tools could need more horsepower than the machine can sustain for a prolonged period of time. 

The performance of the chosen machine tool is also significantly influenced by its stiffness. Also, it is crucial for common tools. 

When removing material, a stiff machine will experience less vibration, enabling higher feed rates and better chip loads. 

There never seem to be enough tool pockets or places, with few exceptions. The cutting tool approach must match the tool capacity of the machine. When complicated components must be machined yet magazine positions are constrained, the use of combination tools to make up the difference may be necessary. Combination tools can also lessen the number of tool changes required to finish a product, improving processing effectiveness. 

The number of spindles, their orientation, and the direction of rotation, together with the relative tool placements, all depend on the machine tool and have an impact on the handedness of the cutting tool. If one or the other is better for the task, custom tools can be made to function clockwise or anticlockwise and with either a right or left hand. Effective chip evacuation can be impacted by selecting one of these orientations over another. 

Other Considerations 

A tool manufacturer must take into account the workpiece features and any other limitations based on fixturing components after understanding the machine information. The next stage in defending bespoke tools is to develop a processing strategy that takes into account the machine’s advantages and disadvantages. 

Custom tooling allows for a more precise match between the material of the cutter and the object being cut. To cut down on processing time or spindle load, efficiency can be adjusted with coatings and geometries tailored to individual materials. 

  • Fixtures that are incredibly stable are also crucial. 
  • Unfortunately, the geometry of the workpiece might not provide the most stable setup and need that equipment is designed with slower feed rates. 
  • Geometric impediments should also be taken into account. 
  • The coolant is obstructed by milled pockets, which makes it challenging to remove chips efficiently. 
  • Chip evacuation is made easier by the use of coolant ports created by a tool. 
  • Non-symmetrical components like stems or posts may limit the diameter or necessitate a longer tool. 

There are numerous live tooling attachments available that boost particular speeds but are physically constrained because of their size. 

Broaching reciprocating attachments have a restricted stroke length but, when used properly, can significantly cut cycle time. 

The constraints of these attachments must be considered during the development of bespoke tools because they are built around attachments like thread whirling and rotary broaching. 

Concluding Note

When a tool manufacturer is aware of a machine’s capabilities, and the requirements for its components, the design of an efficient tool can start. 

When building an application-specific tool, an engineer will take into account these elements as well as the customer’s suggestions. 

Custom tools are extremely useful when the development process is really collaborative because they are application-specific in nature. 

Modern manufacturing techniques guarantee dependability and simplicity of usage. 

So, choose high-quality customized tools. Choose Accusharp!


Coating for Cutting Tools

Coating is necessary for cutting tools.
Following are the main reasons:

  • To Improve Wear Resistance
  • To Improve Heat Resistance
  • To Improve Hardness of Tool
  • To Improve Toughness of Tool
  • To Increase the life of Tool
  • To Increase the Cutting Parameter. 

Accusharp Cutting Tools Pvt. Ltd. has launched an in-house coating plant with the new advanced HiPIMS PVD Coating Technologies – InoxaCon Coating and Ferrocon Coating. While Ferrocon coated tools can be used for machining unalloyed steel, alloyed steel and high-speed steel, Inoxacon coated tools can be used for machining stainless steel, high-alloy steel and titanium. Both the coating technologies use the TiAlSiN (titanium aluminium silicon nitride)-based hybrid PVD coating technology to coat tools.
Accusharp Cutting Tools Pvt. Ltd. is one of the few cutting tool manufacturers in India to bring this high-end technology to the country. “Accusharp has for long been one of the important drivers in the machine tooling industry in India. We are widely recognized as an Indian company with a global business culture, which makes us the first choice for special cutting tools for a number of local companies and MNCs. By investing in HiPIMS technology and bringing InoxaCon and Ferrocon, we are looking to further consolidate our market position. Our customers expect us to provide them with world-class solutions. This is another step in that direction”.


Cutting-Tool Trends in Metalworking and Manufacturing

Since the beginning of time when humans first created metallic artifacts, there have been several tools for cutting metals. By the beginning of the industrial era, the majority of tooling was made of hardened steel in some form, and the basic tool types—turning, milling, and drilling—each with a number of subcategories, were easily distinguished by their distinct geometries.

The discovery of hard metal, sometimes referred to as cemented carbide or simply “carbide,” in 1926 was the one significant development that fundamentally altered the tooling industry. A flood of advancements over the ensuing decades either broadened the performance and/or application range of hard metal tooling or offered substitutes with even superior performance in some applications.

One of the main markets for the powder metal business is cutting tools for use in metal processing. In this case, the latest technologies enable the near-net form production of cutting tools with complicated geometries, a feat not attainable using conventional manufacturing techniques.

Although the fundamental technologies for metal-cutting tools have been around for a while, tool makers still release new items that have the potential to be quite useful.

  • Graphical Progress

New developments in tooling have given geometry more control than ever before. In the case of macro geometry, which is involved in rake face topography, this is particularly true. The degree of slant between the top face of the tool and its cutting edge is referred to as the “rake angle,” and it can significantly affect how your parts and pieces are finished.

In general, larger rake angles have higher cutting power than smaller ones, but they are also more prone to failure and breaking. To discover the optimal rake angle, you must take into account the sort of material you’re working with as well as the precise application of the tool.

  • Nubby Irons

Nodular irons, also known as ductile irons, are becoming more and more well-liked lately. Nodular irons frequently need special equipment to meet the extra development of ferrite materials because they are versatile and manageable materials.

This kind of material is frequently utilized in the manufacture of engine and wheel components for automobiles due to its excellent durability. Despite being very simple to work with, before the artwork is finished, additional finishing procedures are frequently needed to smooth the edges.

  • Drought Machining

In many regions, the development of tools is governed by new and changing regulatory restrictions. To lessen their environmental impact and adhere to 21st-century norms, machinists in these areas have switched to dry machining.

When the material or parts you’re dealing with the need to stay dry throughout the production process, dry machining is the right choice. Cutting fluids and lubricants have the potential to contaminate the finished product, which is a major problem in the manufacturing of medical devices.

Dry machining just cannot be used on some materials. Cutting fluids must be used externally to clean metals like titanium and magnesium in order to prevent damage to the component or your tools.

  • Machined aluminum

While aluminum is still a common material for machining, the sheer variety of aluminum compounds and alloys available necessitates the use of bespoke tools.

The aircraft industry frequently uses titanium aluminide, sometimes known as TiAl. Although its use in the production of engine valves and fans for the automobile industry is being investigated, the material’s hardness and abrasiveness call for a tool with an incredibly sharp edge.

Manufacturers are also using silicon, in particular silicon carbide, to strengthen aluminum without impairing the part’s ability to be machined. The commercial grades of this material have been made available for general production, despite its long history of use in electronics.

  • The Future of Machining and Modern 3D Printing

Modern 3D printers are accessible to the general public, but the manufacturing sector still requires expert machinists to manage large-scale projects, guarantee part consistency, and provide the appropriate finishing equipment for the task. While consumers might be getting ready to start their own small-scale production projects, factories all across the world are merely going about their regular operations.

  • Cermet Cutting Equipment

Cermet cutting tools, which mix ceramic and metal to create a powerful and long-lasting tool, are frequently used in dry machining. When compared to composite materials like tungsten carbide, the resulting tool has greater chemical stability and enhanced hardness when cutting hot materials.

Cermet cutting tools are better suited for making near-net shapes because of their lack of precision, nevertheless. During this procedure, components are created in a shape that closely resembles their final, or net, shape. This reduces the quantity of cleaning, polishing, and edge grinding required to produce a final product.

These could be as simple as an indexable drill-chamfer-spotface combo tool, or they could be a lightweight reamer that was 3D printed. Whatever the necessity, additive manufacturing will have a significant impact on both the producers and consumers of cutting tools. Therefore, the answer to the prior question, “Which is more important: cost, tool life, or predictability,” is clear: It’s all of them, plus data visibility and connectivity for good measure.


Decoding the Top Ways to Extend Cutting Tool Life

When machining, selecting the proper feeds and speeds necessitates striking a precise balance between productivity, part quality, and tool choice. The time required to change tools may negate any productivity benefits, and machinists may burn through their tools too quickly if machines and cutting tools are pushed too hard.

On the other hand, babying machines might increase throughput while lowering tooling costs. We are all aware that time is money in the part-making industry. Because of this, locating the sweet spot of ideal tool life and productivity can seem like an elusive goal that even seasoned programmers and machinists find difficult to achieve.

Here are a few methods that machine operators can use to prolong the life of their tools and determine the ideal ratio of speeds to feeds for each given application.

  • Manage the Heat Through Coolant 

Heat is produced during the cutting process by the friction of chip removal. Your tools may eventually become damaged by high heat. It’s crucial to manage the heat created in this way as much as possible with the use of coolants. The amount of heat produced during the cutting process can be managed with the use of a CO2 coolant system, minimizing the harm done to the tool.

  • Designing Tools Correctly

Making sure a tool has a good design is one of the best methods to guarantee its durability. Cutting tools must remove large amounts of metal quickly and with little strain. These instruments must be able to withstand the strain of multiple simultaneous movements in different directions. A tool that has been appropriately constructed will be able to withstand the demands of the operation without breaking.

  • The Coating

Your cutting tool will be protected from heat damage with special coatings. Cutting tool coatings come in a wide variety, with CVD and PVD coatings being the most common. The CVD coatings are thicker and have good wear resistance, but they don’t stick to sharp edges very well. PVD coatings are thinner yet easier to apply and have superior adhesion to sharp edges. While each of these coatings is appropriate for a different use, they both work to protect your cutting tools from heat damage.

  • When entering and leaving the cut, use caution.

When entering or leaving the cut, cutting tools sustain a tremendous amount of damage. Entering the cut can even chip the tool’s edge on harder materials. Avoid plunging the cutter and enter and exit the cut carefully to prevent this harm. A ramp, helix, or spiral can be used to ensure cuts enter and exit more gently. Consider arcing into the cut for surface and profile cuts. Using an indexable drill to make an entry hole is another approach to guarantee a smoother entry. A cutting tool’s life can be increased and damage avoided by making gentle cuts at the entry and exit points.

  • Adapt your feeds and speeds.

It’s crucial to research the appropriate feeds and speeds for your particular instruments and the metals those tools cut. Tools can be damaged as well as the material being worked on when they are used at the incorrect feed or speed. Even though you might assume the cut’s sound and appearance are sufficient indicators of its accuracy, sometimes you won’t realize the harm that is being done. Look up the feeds and speeds in advance and enter the correct ones into the computer software to prevent this damage and prolong the life of your tool.

  • Never re-cut chips.

After cutting, the metal material can be removed from the workpiece using chips. Additionally, they remove extra heat produced during cutting. However, settings must be right to prevent re-cutting chips from increasing flank wear, crater wear, and other sources of tool wear.

  • Get the edge ready.

The majority of edge preparation entails material removal from the cutting tool. This procedure is crucial to reducing the likelihood of edge chipping, which can result in tool failure. In order to reduce this damage, the edge will be strengthened by preparation. The edge of the material can be prepared using a variety of techniques, including brushing and nylon filament brush honing.

  • Make Sticky Materials Greasy

Some materials have a tendency to adhere to the material the cutting tool is made of. When this sticking happens, it might harm the instrument by welding chips to the cutting edge. To avoid these problems with sticky materials, it’s crucial to lubricate them. This lubrication can be provided by tool coatings, mist coolants, and flood coolants. Your cutting instruments’ lifespan can be increased by lubricating sticky materials.

When entering and leaving the cut, use caution.

When entering or leaving the cut, cutting tools sustain a tremendous amount of damage. Entering the cut can even chip the tool’s edge on harder materials. Avoid plunging the cutter and enter and exit the cut carefully to prevent this harm. A ramp, helix, or spiral can be used to ensure cuts enter and exit more gently. Consider arcing into the cut for surface and profile cuts. Using an indexable drill to make an entry hole is another approach to guarantee a kinder entry. A cutting tool’s life can be increased and damage avoided by making gentle cuts at the entry and exit points.


Industry 4.0 Strategies for Cutting Tools Manufacturers

Industry 4.0, or the “industrial revolution,” is here. Similar to the last three, every industry will experience significant disruption during this time. Technology is undoubtedly advancing, but you must assess your machining operations and processes to ensure that you are prepared to thrive in this new environment. This new industrial revolution’s platforms and technology will alter how you approach your machining operations.

The materials of the future are already being developed, from specialized aircraft metals to polymers, carbon fiber composites, and 3D-printed parts from metal powders.

Aspects of quality control pose the biggest challenge: how can you monitor your production to ensure accuracy? The complexity of cutting tools has increased, as has the demand for accuracy in these machine operations. To retain 10% of the tolerance or 0.2 microns, the cutting tool must be controlled to a size of, say, two microns. It is particularly challenging to set up a batch of tools with precise tolerances since you must measure and make adjustments while manufacturing. In reality, obtaining accurate data or measurements calls for a two-step procedure. Use an in-process measuring instrument when grinding to assist in reducing the possibility of error since it is totally automatic. During the setup, you would use a measurement tool like the Zoller to check the relief geometry. Technology is assisting us in meeting these tight tolerances in this way.

Companies can readily comprehend the complete procedure, make adjustments, and maximize their efforts. In order to grind tools to the exact accuracies required today, a trend may indicate that the coolant system is not maintaining its temperature, for example.

Advantages of precision machining procedures during Industry 4.0

The performance of a machine tool that is Industry 4.0 ready can be significantly increased. The information flow from the machine tool to the product is automated by Industry 4.0. Data about the product that has been manufactured, its correctness, and comprehensive information on the machine tool’s performance are provided by the machine.

Before, a large portion of this took place offline in factories filled with scraps of paper. Information now travels to and from machines electronically and is accessible online. The fundamental data flow that surrounds production is as follows.

Consider that the machine contains a lot of sensors. For instance, each motor has a thermistor that measures temperature to prevent motor overload. All of this sensor data may be collected and used for predictive maintenance with Industry 4.0. It transforms scattered information islands into a comprehensive, detailed collection that is simple to examine.

A central enterprise resource planning (ERP) system can be interfaced with individual computers to provide access to this data. The manufacturing equipment is informed by the ERP system, for instance, that 27 of a particular part are due on a specific day. Although there may not be a reduction in the number of processes, openness about each stage of manufacturing is now available right away and may be anticipated. The efficiency of the machines, the length of time it takes to grind a batch, the most popular items, predictive maintenance, and the caliber of the output are all useful information for factories.

The evolution of machining in Industry 4.0 will continue.

The layer of autonomous quality assurance is fairly new and challenging. The reduction in the actual cost of automation is one feature that represents a significant trend. It has been a while since having a robot maintain a machine was something unusual.

Your machining procedures will be significantly impacted by each of these investments. Machines will be self-sufficient and able to do tasks independently of human assistance. The tooling changes between batches will be managed automatically for upcoming batches. Pallets of materials will be delivered by automatically guided vehicles (AGVs). 

Every working component will be managed by a centralized ERP that is reachable from any type of device. Machine learning and AI will eventually be able to resolve problems that are currently unsolvable.

AI will eventually need to significantly alter the industrial industry. Less labor is being used on the shop floor generally. Making each machine independent requires a lot of work.

Although intimidating, change can also be exciting. You must begin right away if you want to stay competitive in this field. Your rivals’ businesses are benefiting from their investments in Industry 4.0 technologies. It’s time to modernize your machining procedures.

Factories have started making major investments. It is exceedingly challenging to compete with outdated technology due to improvements in quality and performance. You should invest in new technologies as your rivals are already doing so.