1. The most important thing in processing is the tool
Any tool that stops working means production is at a standstill. But that doesn’t mean every knife has the same importance. The tool with the longest cutting time has a greater impact on the production cycle, so under the same conditions, more attention should be given to this tool. In addition, attention should also be paid to machining critical components and tools with the tightest machining tolerances. In addition, tools with relatively poor chip control, such as drills, grooving tools and threading tools, should also be focused on. Because poor chip control can cause downtime.
2. Match with machine tools
Knives are divided into right-hand and left-hand knives, so it is very important to choose the right knife.
Generally, right-hand tools are suitable for counterclockwise rotating (CCW) machine tools (viewed along the spindle direction); left-hand tools are suitable for clockwise rotating (CW) machine tools. If you have several lathes, some holding left-handed tools and others that are ambidextrous, choose left-handed tools. For milling, people generally tend to choose tools that are more versatile. However, although this type of tool covers a larger processing range, it also causes you to immediately lose the rigidity of the tool, increase the deflection and deformation of the tool, reduce the cutting parameters, and are more likely to cause processing vibration. In addition, the manipulator used to replace tools on machine tools also has restrictions on the size and weight of the tools. If you purchase a machine tool with a spindle with internal cooling through holes, please also choose a tool with internal cooling through holes.
3. Match the material being processed
Carbon steel is the most common material processed in machining, so most cutting tools are designed based on optimized carbon steel processing. The blade grade needs to be selected according to the material being processed. Tool manufacturers offer a range of cutter bodies and matching inserts for processing non-ferrous materials such as high-temperature alloys, titanium alloys, aluminum, composites, plastics and pure metals.
When you need to process the above materials, please choose tools with matching materials. Most brands have various series of tools indicating what materials are suitable for processing. For example, DaElement's 3PP series is mainly used to process aluminum alloys, the 86P series is specially used to process stainless steel, and the 6P series is specially used to process high-hard steel.
4.Tool specifications
A common mistake is to choose a turning tool that is too small and a milling tool that is too large. Large-sized turning tools have better rigidity; while large-sized milling cutters are not only more expensive, but also take longer to cut. Generally speaking, larger-format knives are more expensive than smaller-format knives.
5. Choose between replaceable blades or regrindable tools
The principle to follow is simple: try to avoid sharpening your tools. Except for a few drill bits and end mills, if conditions permit, try to choose replaceable insert or replaceable head tools. This will save you labor costs while obtaining stable processing results.
6.Tool materials and grades
The selection of tool materials and grades is closely related to the properties of the material being processed, the maximum speed and feed rate of the machine tool. Choose a tool grade that is more versatile for the material group being machined, typically a coated alloy grade. Refer to the "Grade Application Recommendation Chart" provided by the tool supplier. In practical applications, a common mistake is to try to solve the tool life problem by replacing similar material grades from other tool manufacturers. If your existing tool is not ideal, switching to a similar brand from another manufacturer is likely to produce similar results. To solve the problem, the cause of tool failure must be identified.
7.Power requirements
The guiding principle is to make the best use of everything. If you purchase a milling machine with a power of 20hp, then, if the workpiece and fixture permit, select appropriate tools and processing parameters so that it can achieve 80% power utilization of the machine tool. Pay special attention to the power/speed table in the machine tool user manual and select tools that can achieve better cutting applications based on the effective power range of the machine tool power.
8.Number of cutting edges
The principle is, the more the merrier. Buying a turning tool with twice the cutting edge does not mean paying twice as much. In the past decade, advanced designs have doubled the number of cutting edges in grooving cutters, parting cutters and some milling inserts. It is not uncommon to replace the original milling cutter with only 4 cutting edges with an advanced milling cutter with 16 cutting edge inserts. Increasing the number of effective cutting edges also directly affects the table feed and productivity.
9. Choose integral tool or modular tool
Small-sized tools are more suitable for integral design; large-sized tools are more suitable for modular design. For large-sized tools, when the tool fails, users often hope to get a new tool by simply replacing small and inexpensive parts. This is especially true for grooving and boring tools.
10. Choose a single tool or a multi-function tool
Smaller pieces tend to be better suited for composite tools. For example, a multifunctional tool can combine drilling, turning, internal drilling, threading and chamfering. Of course, the more complex the workpiece, the more suitable it is for multi-functional tools. Machine tools can only bring you profits when they are cutting, not when they are down.
11. Choose standard tools or non-standard special tools
With the popularity of CNC machining centers, it is generally believed that the shape of the workpiece can be achieved through programming instead of relying on tools. Therefore, non-standard special tools are no longer needed. In fact, today non-standard tools still account for 15% of total tool sales. Why? The use of special tools can meet precise workpiece size requirements, reduce processes and shorten processing cycles. For mass production, non-standard special tools can shorten the processing cycle and reduce costs.
12. Chip control
Remember, your goal is to machine a workpiece, not chips, but chips can clearly reflect the cutting status of the tool. Overall, there is a stereotype about chips because most people are not trained to interpret chips. Remember the following principle: good chips will not destroy the machining, bad chips will do the opposite.
13. Programming
When facing tools, workpieces and CNC machine tools, tool paths often need to be defined. Ideally, understand basic machine code and have an advanced CAM software package. Tool paths must take into account tool characteristics such as ramping angle, direction of rotation, feed and cutting speed, etc. Each tool has corresponding programming technology to shorten the machining cycle, improve chips, and reduce cutting forces. A good CAM software package can save labor and increase productivity.
14. Choose innovative tools or conventional mature tools
At the current development rate of advanced technology, the productivity of cutting tools can double every 10 years. Comparing the cutting parameters of cutting tools recommended 10 years ago, you will find that today's cutting tools can double the processing efficiency, but reduce the cutting power by 30%. The alloy matrix of the new tool is stronger and tougher, allowing higher cutting speeds and lower cutting forces. Chipbreakers and grades are less application specific and more versatile. At the same time, modern cutting tools have added versatility and modularity, which together reduce inventory and expand tool applications. The development of cutting tools has also led to new product design and processing concepts, such as overlord knives and large-feed milling cutters with both turning and grooving functions, and promoted high-speed machining, minimum quantity lubrication cooling (MQL) machining and hard turning technology. For these and other reasons, you also need to keep up with the most preferred machining methods and learn about the latest advanced tool technology, or else you risk falling behind.
15. Price
Although the price of the tool is important, it is not as important as the production cost paid for the tool. While knives have their price, the true value of a knife lies in the duty it performs for productivity. Typically, the lowest-priced tools are the ones that cause the highest production costs. The price of cutting tools accounts for only 3% of the part cost. So focus on the productivity of the tool, not its purchase price.
