Technical Sharing | How to Solve the Tool Life Problem? These Methods Are Worth Knowing!
SNSTC 2025-06-25
As an essential tool in machining, the lifespan of a cutting tool directly affects machining efficiency and production costs. A short tool life not only leads to frequent tool replacements and increased costs but also impacts machining accuracy and product quality. So, how can we effectively address the issue of tool life? Today, we’ll share some practical methods with you.
Select the Right Tool Material
Tool material is one of the key factors influencing tool life. Different workpiece materials and machining processes require different tool materials. For example:
High-speed steel (HSS) tools offer good toughness, suitable for machining ductile materials.
Cemented carbide tools offer high hardness and wear resistance, ideal for high-speed cutting.
Ceramic tools have even higher hardness and wear resistance, suitable for machining high-strength, hard materials.
When selecting tool materials, factors such as the nature of the workpiece material, machining process requirements, and machine tool capabilities must be comprehensively considered to choose the most suitable tool material and extend tool life.
Optimize Tool Geometry Parameters
Tool geometry has a significant impact on tool life. Proper geometry can improve cutting performance, reduce cutting forces and heat, and thus prolong tool life. For example:
A larger rake angle can reduce cutting force and heat, but an overly large angle may weaken tool strength.
A larger clearance angle can reduce friction between the tool and the workpiece, though too large an angle can also compromise strength.
Other geometric parameters such as the cutting edge radius, lead angle, and relief angle should also be adjusted based on machining requirements. By optimizing tool geometry, tools can maintain a good cutting condition during machining, reduce wear, and extend service life.
Control Cutting Parameters
Cutting parameters include cutting speed, feed rate, and depth of cut. Reasonable cutting parameters help reduce tool wear and prolong tool life.
Higher cutting speeds generally lead to faster tool wear, while too low speeds reduce productivity.
Excessive feed rates and cutting depths result in higher cutting forces and heat, accelerating tool wear.
Therefore, to extend tool life while ensuring machining quality, use moderate or lower feed rates and depths of cut suited to the application.
Use Appropriate Cooling and Lubrication
Cooling and lubrication significantly reduce cutting temperatures and tool wear, thus extending tool life. Common cooling and lubrication methods include:
Water-based cutting fluids – offer good cooling performance, ideal for high-speed cutting.
Oil-based cutting fluids – offer excellent lubrication, suitable for low-speed cutting.
Compressed air cooling – ideal for dry or environmentally-sensitive machining environments.
The choice of cooling method should consider the workpiece material, tool material, and the specific machining process to achieve optimal results.
Timely Tool Wear Inspection and Maintenance
Tool wear is inevitable, but regular inspection and maintenance can effectively extend tool life. During machining:
Periodically check for wear on the tool’s rake face, flank face, and tip.
When wear reaches a certain limit, perform regrinding or replace the tool promptly.
Keep the tool clean to prevent debris or residue buildup, which can impact performance and lifespan.
Proper maintenance ensures that tools remain in optimal cutting condition throughout the process.
Strengthen Operator Training
The operator’s skill level plays a major role in tool life. Operators should:
Understand correct tool usage and precautions.
Follow machining procedures precisely, including correct tool installation, proper cutting parameter adjustments, and timely tool replacement.
Learn how to detect tool wear and perform maintenance.
By enhancing operator training, improper operations that shorten tool life can be reduced, and tool performance can be maximized.
Conclusion
Tool life has always been a crucial issue in machining. By selecting the right tool material, optimizing geometry, controlling cutting parameters, using appropriate cooling/lubrication, conducting regular inspections and maintenance, and improving operator training, you can effectively prolong tool life, boost productivity, and reduce production costs.
We hope these methods help you solve tool life challenges and improve manufacturing efficiency. If you have further questions or suggestions about tool life, feel free to reach out. Let’s explore and improve together!
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