Cutting tools are very important in many machining processes. They help shape and cut materials to make products we use every day. The type of material used to make these tools significantly affects their performance, durability, and suitable for different tasks.
In this article, we will look at the different types of cutting tool materials. We will also see how they are used in various applications.
Understanding Cutting Tool Materials
Cutting tool materials are specially designed substances that help in removing material from work-pieces during machining processes. These materials need to be hard, tough, and capable of maintaining their cutting edges even under extreme conditions. The choice of cutting tool material depends on several factors, including the type of material being cut, the cutting speed, and the required precision.
Types of Cutting Tool Materials
Here are the most common types of cutting tool materials:
1. High-Speed Steels (HSS)
High-speed steels are one of the most widely used materials for cutting tools. They are known for their excellent hardness and resistance to wear. HSS can withstand high temperatures generated during cutting processes, making it ideal for a variety of machining tasks.
Advantages of High-Speed Steels:
- Good toughness and strength.
- Retain hardness even at high temperatures.
- Suitable for high-speed applications.
Applications: HSS is commonly used in drill bits, milling cutters, and lathe tools.
2. Cemented Carbides
Cemented carbides, often referred to as “carbide,” are made from tungsten carbide particles bonded with a metal binder, typically cobalt. This material is extremely hard and offers excellent wear resistance, making it ideal for cutting tools that need to perform under tough conditions.
Advantages of Cemented Carbides:
- Exceptional hardness and wear resistance.
- Maintains sharp cutting edges longer than HSS.
- Capable of cutting hard materials like steel and cast iron.
Applications: Cemented carbides are used in a variety of machining tools, including milling cutters, inserts for turning tools, and end mills.
3. Carbon Tool Steels
Carbon tool steels are made primarily from iron and carbon. They are less expensive than HSS and cemented carbides but are not as durable. Carbon tool steels are easy to grind, which allows for quick sharpening.
Advantages of Carbon Tool Steels:
- Cost-effective.
- Easy to shape and sharpen.
- Good for making simple cutting tools.
Applications: These steels are often used for making chisels, hand tools, and cutting blades.
4. Ceramic Cutting Tools
Ceramic cutting tools are made from advanced ceramic materials that provide high hardness and resistance to wear. They are less common than HSS and carbide tools but are becoming popular for specific applications.
Advantages of Ceramic Cutting Tools:
- High hardness.
- Excellent wear resistance.
- Suitable for high-speed cutting.
Applications: Ceramic tools are primarily used for finishing hard materials, such as hardened steels and cast iron.
5. CBN and PCD Tools
Cubic Boron Nitride (CBN) and Polycrystalline Diamond (PCD) are two specialized cutting tool materials.
- CBN: CBN is nearly as hard as diamond and is used mainly for cutting hard ferrous materials.
- PCD: PCD tools are very hard and are primarily used for cutting non-ferrous materials like aluminum and copper.
Advantages of CBN and PCD Tools:
- Extremely hard and durable.
- Maintain sharp edges for a long time.
- Ideal for specific cutting tasks involving hard materials.
Applications: CBN and PCD tools are often used in high-precision machining tasks, such as automotive and aerospace applications.
Choosing the Right Cutting Tool Material
When selecting a cutting tool material, consider the following factors:
- Material Being Cut: The type of material you are machining will greatly influence your choice. For softer materials, HSS or carbon tool steels may suffice. For harder materials, cemented carbides or ceramics would be better.
- Cutting Speed: If you need to operate at high cutting speeds, materials like HSS and ceramics will be more effective.
- Cost: Budget constraints also play a significant role. Carbon tool steels are more affordable, while cemented carbides and PCD tools can be more expensive.
- Required Precision: If precision is critical, high-performance materials like CBN or PCD might be necessary.
Maintenance of Cutting Tools
To ensure the longevity and effectiveness of your cutting tools, proper maintenance is essential:
- Regular Sharpening: Keeping your cutting edges sharp is crucial. Dull tools can lead to poor performance and increased wear on both the tool and the workpiece.
- Proper Storage: Store your cutting tools in a dry and clean place. Using protective cases can prevent damage and keep tools sharp.
- Cleaning: After use, clean your tools to remove chips and debris. This helps prevent rust and extends their lifespan.
In summary, the type of cutting tool material you choose can significantly impact your machining results. High-speed steels, cemented carbides, carbon tool steels, ceramics, CBN, and PCD all have unique properties that make them suitable for different applications. Understanding these materials will help you select the right cutting tools for your projects, leading to better performance and efficiency. Whether you are a hobbyist or a professional, knowing about cutting tool materials is essential for achieving high-quality results in your machining tasks.