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Three elements of cutting technology system and tool application technology
Since the 1980s, driven by high technologies such as information technology, machining has entered a new phase of development characterized by "high-speed, high-efficiency, intelligence, integration, and environmental protection." Innovations like high-speed (effective) cutting, near-net forming, flexible processing, five-axis machining, multi-process machine tools, network manufacturing, and green manufacturing have emerged. These technologies have significantly enhanced the manufacturing industry by improving processing efficiency and quality, reducing costs, shortening lead times, protecting the environment, and lowering energy and resource consumption. Among these, advancements in cutting technologies and tools stand out as one of the most critical processes in modern advanced manufacturing. They are essential for developing new products, processes, and applying new materials, serving as key technologies in the innovation systems of metalworking companies.
As modern cutting technology continues to evolve, the application of cutting tools plays an increasingly vital role. The ability of a tool to generate value for users depends not only on its design and production but also on the proper use under appropriate processing conditions. Tool manufacturers now provide application technologies to meet user needs, helping them increase efficiency, reduce costs, improve quality, or develop new products and materials. This has made tool application technology a core area for toolmakers, receiving growing attention. For end-user companies, enhancing their use of tool technology can unlock existing processing potential, boost efficiency, and lay the groundwork for future product and process innovations.
Metal cutting is a complex, multi-factor process, and the application of cutting tools involves a wide range of content. In this lecture, we analyze the cutting process to identify the main factors that influence it, providing a foundation for understanding common tool application techniques. The goal is to help users apply tools correctly and effectively.
Figure 1 shows a simplified diagram of turning and related terms. The cutting process occurs in the cutting zone, where the tool interacts with the workpiece. As the workpiece material passes through this zone, it transforms into chips and is discharged along the rake face. The enlarged view highlights the interaction between the tool and the workpiece. During cutting, the material layer to be removed enters the deformation zone. Under the action of the tool’s rake face, deformation and lattice slippage occur, resulting in shear along the imaginary slip plane OA, which becomes the chip. As the chip discharges, friction occurs between the fresh metal surface underneath and the rake face in the OB section, forming the rake face friction area. Meanwhile, the machined surface, after slipping past the tool tip, experiences friction with the flank face in the OC section due to material springback, creating the flank friction area. The tool then operates under the combined forces and heat from both the deformation and friction zones.
It is clear that the tool and the workpiece material are central to the cutting process. However, supporting technologies are necessary to achieve the entire cutting process. As a metal processing technique, the metal cutting process can be described by the technical system shown in Figure 2. The system consists of three parts: the cutting process system, the cutting mechanism, and the machining effects, divided by dotted lines. The first part is the cutting technology process system, consisting of the machine tool, the tool, and the workpiece. Machine tools and cutting tools are indispensable for cutting operations. Depending on the movement and power provided by the machine tool, excess metal is removed from the workpiece using a cutting tool, producing the desired shape.
To further understand the cutting process, it is important to refine the technical aspects of the tools, machine tools, and workpieces. The tool is a crucial component of the cutting process. It contains three main technical elements: tool material and coating, geometric angles, and tool structure. The tool must be made from special materials, with defined geometry and suitable structure. These three elements together give the tool its cutting function and determine its performance. Therefore, the content and role of these factors are key aspects of cutting technology.
Cutting technology related to machine tools includes cutting parameters, process types, and cutting conditions. The machine tool provides a technological platform for various cutting operations, including the power required for cutting, the relative motion between the tool and workpiece, cooling lubrication conditions, and reliable clamping. The speed of the relative motion between the tool and workpiece, the cutting speed of the main movement, and the feed speed of the auxiliary movement are the two main cutting parameters. Machining requires the machine to have sufficient power, rigidity, high speed, and automation, as well as accurate movement and positioning. Therefore, the performance of the machine tool plays a critical role in the effectiveness of the cutting process and is closely related to its level. Understanding and mastering the performance of the machine tool and using it correctly are prerequisites for specific machining. Both machine tools and cutting tools promote each other, jointly advancing the progress and development of cutting technology.
The workpiece is the object being cut and is also a key part of cutting technology. Its dimensional accuracy, surface quality requirements, material, and structure all affect the cutting process. Setting cutting parameters and designing tool geometry must adapt to the specific characteristics of the workpiece. In particular, the machinability of the workpiece material has a significant impact on the cutting process and has become an important technical aspect. Currently, the engineering materials that need to be machined have gone beyond traditional metals. Non-metallic materials and new synthetic materials are increasingly used as engineering materials, becoming a new frontier in cutting technology.
The second part of the cutting technology system is the mechanism of the metal removal process, including the cutting deformation process and two important physical phenomena: cutting force and cutting heat. Cutting forces and heat from the deformation zone convey internal information about the cutting process and have a major influence on it. The forces required to push the tool, cut off the metal, and the friction between the tool and the workpiece and chip form the cutting system force. The machine's drive system must overcome these forces and provide sufficient power. Cutting forces cause deformation of the machine tool, tool, and workpiece, affecting machining accuracy. The cutting forces and friction acting on the tool cause tool wear and damage. In the relative motion between the tool and workpiece, the heat generated by the cutting force also causes deformation of the process system and worsens tool wear and damage.
Reducing cutting forces and heat, lowering cutting temperature to slow tool wear and prevent damage has become an important basis for setting cutting parameters and selecting tools. Since tool wear and failure are direct consequences of cutting forces and heat, the size, speed, topography, and failure characteristics of the tool are all related to these factors. Therefore, it is an essential basis for analyzing and understanding the cutting process. The key to application technology. Figure 3 shows a typical wear diagram of a turning tool, illustrating the wear appearance around the tool tip and representing other tools. Figure 4 shows various wear and damage appearances and causes of the turning tool under the action of force and heat. Effective measures to reduce wear or prevent breakage are the main thread throughout the tool application technology.
Currently, high-speed steel tools account for approximately 35% of global tool sales. The world tool consumption market is calculated based on product sales. General machinery and automotive manufacturing each account for about 35%, while aerospace accounts for about 10%, among which are high-speed steel cutters.
**Focus on High-Speed Steel Cutters**
Mr. Shen Hong, Honorary Chairman of the China Association of Blades, once said, “Tools are small but powerful.†Indeed, cutting tools are the most dynamic factor in machining. As a manufacturing powerhouse, China’s machine tool consumption is already the highest in the world. Manufacturing companies increase their investment in cutting tools to boost productivity and gain greater benefits, which drives the rapid growth in cutting tool purchases. Currently, annual sales of foreign cutting tools in China have reached $500 million, with Sandvik Coromant achieving annual sales of 1 billion yuan, and an average growth rate of 23% over the past decade. In the first three quarters of 2007, the tool sales of 650 domestic tool companies reached 11.8 billion yuan, a year-on-year increase of 27.1%. The huge market potential has triggered investments in the tool industry. Companies like Zhuzhou Diamonds and Xiamen Jinlu have launched indexable cutting tool projects, Jiangsu Tiangong introduced tapping and grinding drill production lines, and foreign investments such as Kennametal’s Tianjin plant and Iska’s Dalian plant, as well as Sandvik’s equity participation in Xiamen Jinlu, include both hard alloy and high-speed steel cutting tools. These developments show that high-speed steel cutters occupy an irreplaceable position in modern manufacturing. We must pay attention to high-speed steel cutting tools and vigorously develop them.
In recent years, high-speed steel materials and high-speed steel cutting tool technology have made great progress. First, high-performance high-speed steels such as M42, M35, and China-specific aluminum high-speed steel (commonly known as 501 or M2Al) can reach HRC 69–70 after heat treatment. Powder metallurgy high-speed steel hob cutting steel gear speeds have reached 150–180 m/min or higher, and powder metallurgy high-speed steel cones can process gray cast iron threads at 65 m/min. Second, compared to hard alloys, high-speed steel has high strength and toughness, making it the preferred choice for manufacturing complex tools and drilling tools. According to statistics, 33% of milling cutters, 95% of taps, 51% of twist drills, 81% of gear cutters, 86% of broaches, and 95% of saw blades are made of high-speed steel. Among them, 70% of gear cutters, 50% of broaches, 20% of end mills, and 10% of taps are made of powdered high-speed steel. Third, high-speed steel tools have sharp edges, light cutting, and are less likely to cause work hardening during cutting, giving them advantages in processing stainless steels, nickel-based alloys, and titanium alloys. When cutting such difficult-to-machine materials, we should not limit ourselves to hard alloys but can also try high-speed steel drills and milling cutters with large rake angles and sharp cutting edges.
In Europe, there is an institution called the High Speed Steel Research Forum. Through research and training, it is dedicated to the development and application of high-speed steel technology. Taking a moment to browse its website will yield valuable insights.
High-speed steel tools currently account for about 35% of the world’s total tool sales. The world tool consumption market is calculated based on product sales. General machinery and automobile manufacturing each account for about 35%, while aerospace accounts for about 10%, among which are high-speed steel cutters. Friends from U.S. companies and foreign trade firms who worked at Boeing shared a message: a large number of high-speed steel twist drills are used in aircraft manufacturing. If a twist drill can drill 7–8 spring steel plates of trucks, it may be accepted by Boeing.
China is now the largest producer of high-speed steel and high-speed steel cutting tools globally. The production and export volume of high-speed steel and high-speed steel cutting tools (mainly twist drills) are the highest in the world. In 2006, products from Shanggong, Jiangsu Tiangong, Jiangsu Feida, Harbin, and Chenggao high-speed steel cutting tool twist drills won the titles of Chinese famous brand products. These products have gained recognition in European and American industrial markets, indicating that China’s high-speed steel cutting tools have made significant progress in both scale and quality.
Economists expect that the rapid growth of the Chinese economy and the development of the manufacturing industry will continue for at least 10 years, offering unprecedented opportunities and challenges to the cutting tools industry. Currently, high-speed steel tools account for about 75% of the domestic tool market, but powdered high-speed steel materials and some high-end high-speed steel tools are still heavily dependent on imports. We must vigorously develop high-speed steel cutting tools, including the development of new high-speed steel grades, especially powdered high-speed steel, to create more and better high-speed steel cutting tools and strive to improve application levels. It is believed that through the joint efforts of all cutting workers and comprehensive innovations in tool materials, tool structure, manufacturing processes, and application technologies, we will certainly elevate the level of development and application of Chinese high-speed steel cutting tools to a new height, making tangible contributions to the revitalization of China’s cutting technology.