Cutting costs with tool reconditioning

High-performance cutting tools can provide increased efficiency and productivity, but they can also be a drain on tooling budgets. Cost-justifying these tools often requires regrinding and reconditioning them when they are worn or damaged. A successful reconditioning program reduces tooling costs by extending life as long as possible.

While costly, high-performance cutting tools and advanced machine tools are needed when performing high-speed machining, hard milling, thread milling and helical pocketing—operations that were uncommon in the not-too-distant past. These machining processes require cutting tools produced to exacting standards and close tolerances, which increases the complexity of the reconditioning process.

Reconditioning has grown so complex that is rare to find a shop that does not send its tools to a reconditioning shop. That’s because reconditioning high-performance cutting tools requires more than a conventional tool and cutter grinder and a pot of hot wax. Multiaxis CNC tool grinders and superabrasive wheels have replaced Monoset grinders and vitrified wheels.

Courtesy of All images: Walter USA

A description of the Walter Titex tool reconditioning program. Walter is one of the cutting tool suppliers at Savannah Machinery Works.

Therefore, successful reconditioning requires finding and partnering with the right reconditioning company, and it may require partnering with more than one. In most cases, a good cutting tool distributor can usually help you find one or more suppliers with good reputations.

Complex tool geometries, multilayer coatings and demanding tool manufacturing processes are often closely guarded secrets. In some cases, only the tool manufacturer can accurately recondition its tools, and most major toolmakers provide reconditioning services that return tools to OEM specifications and come with a performance guarantee. Take advantage of their expertise and willingness to absorb the risk of improper reconditioning.

A reconditioning program that maximizes cost benefits must be thoughtfully developed and actively managed. Correct tool application in the machining process is the first step toward developing a successful reconditioning program.

Major toolmakers provide engineering support and typically help develop efficient machining processes. Engaging toolmakers and learning to properly apply their tools helps prevent damage caused by misuse. Damaged flutes and chipped corners can quickly cause catastrophic tool failure and possibly scrap the part being machined. In addition, damaged tools cost more to recondition than worn tools since regrinding them is more complicated.