Cutting Tools

Round-up of five recently introduced indexable tools: stub drill, universal
milling cutter, center-cutting endmill, dovetail cutter and insert clamp.

The author, an expert on cutting tool edge preparation, explains the importance of applying the proper edge hone to a tool. He also discusses a brush-type honing machine designed to apply a variable edge--a capability not available with other machines on the market.

Ion implantation bombards a tool's surface with accelerated metal ions. According to this article, the process increases tool life and the performance of tool coatings. Two theories explaining why the process works are also discussed.

This article discusses the trend among insert makers to consolidate chipbreaker designs and carbide grades. The result is the three-chipbreaker/three-grade matrix many insert makers have adopted in some form. The evolution of the chip-forming groove is also traced, and an ANSI proposal for a grade identification system is described.

This article reviews the nomenclature that toolmakers use to identify inserts. Both ANSI and ISO codes are described character by character. A chart lists all of the possible choices for each position in the code and what each code letter or number signifies.

Changes in milling practices have placed new demands on the cutting tool. This article discusses the features toolmakers have added to their milling insert geometries to control chips and cutting forces. The article also reviews the milling process and the forces that act on the insert.

Tunable tools can be adjusted to dampen vibration. However, shops must have the right equipment to tune them quickly and precisely. This article describes an instrument that can provide the necessary feedback. A system that uses a mill's vibration frequency to sense problems with the tool is also described.

The development of the CVD thick-film diamond process has made it possible to produce tools that can machine abrasive work materials without losing their cutting edge. In this article, the technology for producing the diamond film and the brazing of these thick-film chips onto inserts is described.

High-performance aluminum-alloy workpieces are prone to residual stresses that can lead to part distortion. This article reviews the milling tools and practices that affect these stresses. Some tools and practices alleviate the stress, while others allow the machinist to mill the part without adding more stress.

Cermet inserts have evolved into cutting tools capable of finish-turning steel reliably at high speeds. This article traces the developments that have led to modern cermets and describes the properties that enhance the performance of these tools. The development of coatings for cermets is also covered.