When choosing the tool angle, several factors must be taken into account, such as the workpiece material, tool material, and machining properties. In general, the tool angle refers to the angle marked for manufacturing and measurement purposes. However, in practical applications, the actual working angle may differ from the marked angle due to variations in the tool's mounting position and the direction of the cutting motion. Despite these differences, they are usually minor and do not significantly affect performance.
The material used for making tools needs to possess high hardness at elevated temperatures, excellent wear resistance, sufficient bending strength, impact toughness, chemical inertness, and good machinability. These properties ensure that the tool can withstand the harsh conditions encountered during cutting operations.
Typically, materials with higher hardness also exhibit better wear resistance. Similarly, materials with greater bending strength tend to have higher impact toughness. However, there is often a trade-off: as hardness increases, bending strength and impact toughness may decrease. Due to its combination of high flexural strength, good impact toughness, and favorable processability, high-speed steel remains the most widely used tool material. Following it in popularity are hard alloys, which offer superior hardness and wear resistance.
Polycrystalline cubic boron nitride (PCBN) is ideal for machining very hard materials like hardened steel and hard cast iron. Polycrystalline diamond (PDC) is suitable for cutting non-ferrous metals, as well as composites, plastics, and glass-reinforced materials. Meanwhile, carbon tool steel and alloy tool steel are now mainly used for simpler tools such as trowels, dies, and taps.
Modern carbide indexable inserts are often coated using chemical vapor deposition (CVD) techniques, with layers of titanium carbide, titanium nitride, alumina, or composite hard coatings. The physical vapor deposition (PVD) method has also gained popularity, not only for cemented carbide tools but also for high-speed steel tools like drills, reamers, taps, and end mills. These hard coatings act as barriers against chemical diffusion and heat transfer, reducing tool wear and extending tool life by approximately 1 to 3 times compared to uncoated tools.
With increasing demands for high-temperature, high-pressure, high-speed machining environments and the use of more challenging materials, the need for advanced cutting tools has grown. Automation and precision in machining processes are continuously improving. To meet these challenges, future developments in tool technology will focus on creating new tool materials, further advancing coating technologies to achieve higher hardness on tough and strong substrates, and optimizing tool design to better balance hardness and strength. Additionally, improvements in manufacturing precision, quality consistency, and efficient tool usage will remain key priorities.
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Labels: Tool material, Impact toughness, Difficult-to-process materials, Physical vapor deposition, Metal processing
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