1

Cutting Tools
One of most important components in machining process
Performance will determine efficiency of operation
Two basic types (excluding abrasives)
Single point and multiple point
Must have rake and clearance angles ground or formed
on them
2
Cutting-Tool Materials
Toolbits generally made of seven materials
High-speed steel
Cast alloys (such as stellite)
Cemented carbides
Ceramics
Cermets
Cubic Boron Nitride
Polycrystalline Diamond
3
Cutting Tool Properties
Hardness
Cutting tool material must be 1 1/2 times harder than the
material it is being used to machine.

Capable of maintaining a red hardness during
machining operation
Red hardness: ability of cutting tool to maintain sharp cutting
edge
Also referred to as hot hardness or hot strength


4
Cutting Tool Properties
Wear Resistance
Able to maintain sharpened edge throughout the cutting
operation
Same as abrasive resistance

Shock Resistance
Able to take the cutting loads and forces

Shape and Configuration
Must be available for use in different sizes and shapes
Evolution of Tooling Materials
6
High-Speed Steel
May contain combinations of tungsten, chromium,
vanadium, molybdenum, cobalt
Can take heavy cuts, withstand shock and maintain
sharp cutting edge under red heat
Generally two types (general purpose)
Molybdenum-base (Group M)
Tungsten-base (Group T)
Cobalt added if more red hardness desired
7
Cast Alloy
Usually contain 25% to 35% chromium, 4% to 25% tungsten
and 1% to 3% carbon
Remainder cobalt
Qualities
High hardness
High resistance to wear
Excellent red-hardness
Operate 2 times speed of high-speed steel
Weaker and more brittle than high-speed steel
8
Carbide Cutting Tools
First used in Germany during WW II as substitute for
diamonds
Various types of cemented (sintered) carbides
developed to suit different materials and machining
operations
Good wear resistance
Operate at speeds ranging 150 to 1200 sf/min
Can machine metals at speeds that cause cutting
edge to become red hot without loosing harness
Tool Life in Steel
High Speed Steel

Solid Carbide

TiN Coated

TiCN Coated

AlTiN ( TiAlN )
Tool Life
Cost
Higher
Lower
Solid Carbide vs. High Speed Steel
HSS = 58-62 Rc (approx.80-82 Ra)
Solid Carbide = 89-94 Ra
Increase in Hardness Provides:
Use Higher Speed and Feeds
Longer Lasting Cutting Edges
Carbide Retains Hardness at Elevated Temperatures
Carbide Grades
Carbide is a Composite ( WC )
Tungsten Carbide Particle Sizes: From 0.4 um to 1.2 um
Different Percentages of Cobalt Used as a Binder Material
Effect of Grain Size on Carbide Properties
As grain size decreases:
Hardness increases
Impact strength may decrease
Edge strength increase
As grain size increases:
Hardness decreases
Impact strength may increase
Edge strength decrease

10% Cobalt ( Co )
0.6 um Tungsten Carbide ( WC )
grain size
10% Cobalt ( Co )
1.2 um Tungsten Carbide ( WC )
grain size
WC WC
WC
WC
WC
WC
WC
WC
WC
WC
WC
Co
WC
Co
WC
WC
WC
Effect of Cobalt % on Carbide Properties
As Cobalt % decreases:
Hardness increases
Impact strength decrease
Stiffness increase
As Cobalt % increases:
Hardness decreases
Impact strength increase
Stiffness decrease

10% Cobalt ( Co )
0.6 um Tungsten Carbide ( WC )
grain size
15% Cobalt ( Co )
0.6 um Tungsten Carbide ( WC )
grain size
WC WC
WC
WC
WC
WC
WC
WC
WC
WC
WC
Co
WC
WC
WC
WC
WC
WC
WC
WC
Co
Grade Selection
As Cobalt 6 % and
1.3~1.5 um Grain Size
Non - Ferrous or
Non - Metal
As Cobalt 10 % and
0.8 um Grain Size
Ferrous or
Long Reach
As Cobalt 14~16 % and
0.8 um Grain Size
Tougher Ferrous
Tool Coatings
More Application Specific Coatings Available :
TiN ( Titanium Nitride )
TiCN (Titanium Carbon Nitride )
TiAiN (Titanium Aluminum Nitride )
Diamond
Tool Coatings Provide
Cutting Edge Protection
Added Lubricity
Higher Cutting Speeds
Not all Carbide Grades are compatible with all tool coatings
Strict cleaning and handling procedures required
Tool Coatings are NOT a substitute for: -
Improper Geometry for an Application
Poor Quality Tools
Improper Carbide Grade for an Application
Tool Material and Coatings
( Micro-Grain Carbide )
Applications & Benefits : General Purpose Use

Wide range of materials
High feeds & speeds
Micro-Grain Carbide : Color Gray
Micro hardness 2000 Vickers
(Approx.. 70-75 Rockwell C)
Tool Material and Coatings ( TiN )
Applications & Benefits : General Purpose Use
Wide range of materials
3 to 8 times longer tool life than carbide
Higher feeds & speeds

Titanium Nitride ( TiN ) : Color Gold / Yellow
Film Thickness 1- 5 Microns
Microhardness 2300 Vickers
( Approx. 80-85 Rockwell C )
Tool Material and Coatings ( TiCN )
Applications and Benefits :
High Performance Applications

Difficult to machine materials
Higher speeds and feeds possible for enhanced machining
productivity
Wear resistance and toughness superior to TiN
High speed machining
Materials up to 40 ~ 50 Hrc
Tool Material and Coatings ( TiCN )
Titanium Carbonitride ( TiCN )
Color :- Blue / Gray
Film Thickness 1- 5 Microns
Microhardness 3000 Vickers
(Approx. 90 Rockwell C)
Applications and Benefits :
High Performance Applications
Difficult to machine materials
Higher speeds and feeds possible for enhanced machining productivity
Wear and heat resistance superior to TiAlN
High speed machining
Hardened Materials to 60 HRc
Tool Material and Coatings ( TiAlN )
Aluminum Titanium Nitride (TiAlN)
Color : Purplish / Black
Film Thickness 1- 5 Microns
Microhardness 4500 Vickers
(Approx. 95 Rockwell C)
Tool Material and Coatings ( TiAlN )
Applications & Benefits : General Purpose Use
Use for non-ferrous materials (aluminum and graphite)
15 times longer tool life than TiN coated tools
Higher feeds & speeds

COATING Diamond : Color : - Black
Film Thickness 10 Microns
Microhardness 3200 Vickers
(Approx. 90-95 Rockwell C)
Tool Material and Coatings ( Diamond )
Coatings for hardened material
H.S.S High Spees Steel 30 HRC
W.C Micro grain carbide 40 HRC
TiN Titanium Nitride 40 HRC
TiCN Titanium Carbon Nitride 45 ~ 50 HRC
TiAlN Titanium Aluminum Nitride 50 ~ 62 HRC
Alternatives to Carbide
Compared to carbide, the materials listed here tend to offer
higher hardness (including hot hardness) but lower
toughness. Whether or not any one of these tools can justify
its cost premium over carbide will vary from application to
application. Find the right cutting tool by testing various
alternatives in your process.

Ceramic:
Ceramics used to mill and drill cast iron are silicon
nitride based. They are effective in machining gray
cast iron, and often deliver more tool life as speeds
increase. In fact, ceramics generally should not be
run at speeds lower than 650 sfpm. In drilling,
ceramic tools are at their most effective in holes no
more than 4 diameters deep.

Cermet :
Cermet (CERamic METal) consists of ceramic
particles in a metal binder. Cermet tools can be used
in both cast iron and cast aluminum, as well as in
many other materials. In milling, cermet is typically
thought of as a finishing tool because it can often
produce surface finishes superior to what carbide
can achieve. However, cermet milling cutters can
also stand up to heavier cuts.


CBN & PCD:
CBN (Cubic Boron Nitride) and PCD
(Polycrystalline Diamond) are expensive tool
materials, but in certain high speed machining
applications they can deliver long tool life, as
in the part shown below. CBN and PCD are
applied either as coatings to solid tools or on
the tips of inserts. CBN is used for ferrous
applications, PCD for non-ferrous.


Manufacturing of CBN/PCD Inserts
Protect Against Shocks
Ceramic, cermet, CBN, and
PCD are all more likely than
carbide to chip or crack as a
result
of vibration or thermal shock.

Hot hardness characteristics of engineering tool material
Hardness vs. toughness for various cutting materials
Speed Vs Feed -Suitability