Gathered from machine shop and application experts’ cutting-tool philosophies and trade tricks, here are 20 productivity tips, application insights and general knowledge on how to get an edge in performance and service life.

Machine tool consumption in the United States totaled $3,080.61 million in 2005, up 8.4 percent from the year prior. As machining and tooling obviously still is a key factor in manufacturing, let’s take a look at some general insights and productivity tips regarding cutting-tool philosophy, here via Modern Machine Shop and Modern Application News:

1. The Costs that Count
Focus on cost per part, not the cost of cutting tools, as a key target. Because cutting tools account for only three percent of total production costs in metalworking, upgrading cutting tools is likely to yield more overall cost savings.

2. Cutting Tools are a System
Keep both hardware (e.g., cutter bodies and toolholders) and software (e.g., indexable inserts) up to date. When looking at an upgrade in insert technology, consider upgrades in toolholders and cutter bodies, and vice versa.

3. Target and Elucidate
When engineering a new process or troubleshooting an existing one, target four main areas and set clear, measurable goals for each: cycle time, tool life, part quality and surface finish. Then rank by priority. Share those goals and priorities with your vendors for better answers sooner.

4. Troubleshooting: Process Problem or Tooling Problem?
Don’t be too quick to blame the tool. Instead, use the mode of tool failure as a clue to the root problem. Look at machine rigidity, feed, speed, depth of cut, presentation angle, chip clearance and coolant. If it is a tooling problem, changing the tool will fix it. If the problem is a process problem, it probably won’t matter what tool you use.

5. Coatings Aren’t Only for Inserts
Coat cutter bodies to get some important benefits that high-tech coatings bring to carbide inserts: hard coatings on cutter bodies resist wear from contact with hot chips moving at high speeds; chips flow more readily through flutes because the coating gives the surface lubricity.

6. Multifunction Tools for Multitasking Machines
Added spindles, tool turrets and rotational axes mean tight clearances and a limited number of tool stations, so consider the possibility of having one toolholder with several multipurpose inserts that can do facing, OD turning, drilling, counter drilling and internal threading without a tool change.

7. Modular Thinking is Lean Thinking
To keep tool inventory at a more manageable level, consider modular tooling shanks that accept a variety of interchangeable solid carbide heads. As the heads can be replaced or exchanged while the tool is clamped in the machine, setup time can be reduced.

8. Don’t Neglect Power Consumption
Besides energy savings, cutting tools that require less power from the machine tool tend to last longer, cause less wear and tear on spindles and ways, and minimize vibration. A 10 percent reduction in cutting forces is likely to result in a 50 percent improvement in tool life.

9. Get Clamping Forces Right
When tightening the clamping screws after indexing an insert, DO NOT GUESS about the torque applied. Under-tightening may allow the insert to chatter or prevent the process from holding tolerances, while over-tightening may break the insert or the key. For a simple way to eliminate uncertainty, consider a torque wrench that automatically lights up to signal that proper tightening levels have been reached.

10. Can Your CAM Software Keep Up?
When programming for CNC operations, it is important for toolpaths to match the capability of the cutting tools. Not all CAM software allows the programmer to program the moves that optimize the performance of advanced cutting tools.

11. Think Process First
Sometimes taking an unconventional approach is the answer. Especially on larger holes in one-off or short-run work, milling a hole from solid with helical milling often makes more sense than drilling it. Large-diameter drills may be faster, but they’re a lot more expensive and not near as versatile.

On average, plunge milling can remove material four times faster than slab milling.

(via American Machinist)

12. Understand Cutting-Metal Forces, Use Them to Advantage
Cut in a direction that improves rigidity of the setup. Consider reducing the depth of cut to convert radial forces into axial forces. Then increase the feed rate to take advantage of higher axial rigidity.

13. Take Advantage of Tool Geometry
This can improve throughput. For instance, on lead-angle cutters, increase the feed rate to achieve maximum recommended chip thickness.

14. Match Tool Geometry to Material Being Cut
Especially in job shops handling a variety of workpiece materials, beware of “general purpose” tooling. Take the time to change tools when you change materials. You’ll get more throughput and make more money that way. Again, the price tag on the tooling is the least important part of the process-economics equation.

15. No Vibes Are Good Vibes
Minimizing or eliminating vibration is usually a matter of controlling cutting forces so that they are directed to the most stable, most rigid element of the machining system. Upon every proposed change in tooling, examine how vibration is managed. That is the key to prolonging tool life, protecting the spindle and improving surface finish.

16. The True Meaning of “Indexable”
To make sure you are getting the full value of the original concept of carbide inserts with indexable edges, look for styles that offer the most in multiple edges and be sure the edges truly are usable.

17. Combining Process and Cutting Your Time in Cut
Combining several processes into one makes can increase efficiency and reduce costs. The time required for the separate machining cycles, as well as the time required for tool changes, can be reduced or eliminated. Further, tooling costs can be reduced by reducing the number of tools required for a job. (See also Tip 6.)

18. Understand Heat
Know where heat comes from and how it can help or hurt you. Metalcutting will always generate heat, not all of it from friction. In steel machining in particular, you want only enough heat to soften the workpiece material and form good chips. Avoid heating levels that can trigger hardening reactions in the material, overheat the tool or decarburize (crater) the insert.

19. Maximize Your Liquid Assets
For coolant-fed drills, there are two parts to the battle: getting the coolant to the cutting edges and getting the chips out of the hole effectively. Thus, coolant flow and chip flow must be considered equally.

20. Return to School
Companies sending their engineers and programmers back to classes often see a fresh return on their investment each time, a return that comes usually within weeks of completing the class. Their people come back excited to apply their new knowledge right away. Some of the excitement may rub off on co-workers. If you’ve tooled a job the same way for more than three years, odds are there’s a better way that will make you more competitive.

Sources

Upgrade Your Cutting Tool Mindset
by Mark Albert
Modern Machine Shop, July 2005

Teacher’s Top 10 Tooling Tips
by Dave Eisele
Modern Application News, July 2004

Additional

Get an edge on tool performance
by James Benes
American Machinist, December 2005