Abstract

This paper focuses on the optimization of cutting tool performance, aiming to explore effective strategies for enhancing machining efficiency and extending tool life. It first analyzes the key factors affecting cutting tool performance, including tool materials, geometries, cutting parameters, and machining conditions. Then, through in - depth research on advanced coating technologies, optimized tool designs, and intelligent machining control methods, it systematically expounds on specific strategies for improving cutting tool performance. Case studies from various manufacturing industries are presented to demonstrate the practical effectiveness of these strategies. The research provides valuable references for manufacturers and engineers to optimize cutting tool applications and improve overall machining productivity.

Keywords

Cutting tool; Performance optimization; Efficiency; Tool life; Machining

1. Introduction

In modern manufacturing, cutting tools play a crucial role in machining processes. Whether in the production of automotive components, aerospace parts, or general mechanical products, the performance of cutting tools directly impacts machining quality, production efficiency, and manufacturing costs. Optimizing cutting tool performance to enhance machining efficiency and extend tool life has become an urgent need for manufacturing enterprises to improve their competitiveness. This paper comprehensively explores various strategies for achieving this goal, integrating theoretical analysis and practical experience.

2. Key Factors Affecting Cutting Tool Performance

2.1 Tool Materials

The choice of tool material significantly determines the cutting tool's performance. Traditional materials such as high - speed steel (HSS) are known for their good toughness and ease of machining, making them suitable for low - to medium - speed cutting operations, especially for complex - shaped tools like drills and end mills. However, their relatively low hardness and heat - resistance limit their application in high - speed and high - precision machining.

Carbide, on the other hand, has higher hardness, wear - resistance, and thermal conductivity compared to HSS. Cemented carbide tools, composed of tungsten carbide particles bonded with cobalt, can withstand higher cutting speeds and temperatures, making them widely used in turning, milling, and drilling of various metals. For extremely hard materials or high - speed machining, superhard materials such as cubic boron nitride (CBN) and diamond - like carbon (DLC) coatings offer superior performance. CBN is highly resistant to abrasion and can operate at high temperatures, making it ideal for machining hardened steels. Diamond - based tools have excellent hardness and low friction, suitable for cutting non - ferrous metals and non - metallic materials, but their reactivity with iron limits their use in ferrous metal machining.

2.2 Tool Geometries

Tool geometries, including rake angle, clearance angle, and cutting edge radius, influence the cutting forces, chip formation, and heat generation during machining. A positive rake angle reduces cutting forces by facilitating the flow of chips, but it may weaken the cutting edge and reduce tool life under heavy cutting conditions. In contrast, a negative rake angle strengthens the cutting edge, making it more suitable for interrupted cutting or machining hard materials, although it increases cutting forces.

The clearance angle determines the space between the tool flank and the newly machined surface, preventing rubbing and reducing heat generation. An appropriate clearance angle ensures smooth machining and extends tool life. The cutting edge radius affects the cutting edge strength and the quality of the machined surface. A smaller cutting edge radius can achieve a finer surface finish but may be more prone to chipping, while a larger radius enhances edge strength at the cost of increased cutting forces.

2.3 Cutting Parameters

Cutting parameters, namely cutting speed (

v

), feed rate (

f

), and depth of cut (

a 

p

), have a direct impact on cutting tool performance. Increasing the cutting speed can improve machining efficiency, but it also raises the temperature at the cutting zone, accelerating tool wear. Each tool - material combination has an optimal cutting - speed range within which the tool life is maximized.

The feed rate determines the amount of material removed per revolution of the tool. A higher feed rate increases material removal rate but may lead to poor surface finish and increased tool wear due to higher cutting forces. The depth of cut affects the load on the cutting tool. A large depth of cut can remove more material in one pass, but it also increases the stress on the tool, potentially causing premature failure. Balancing these three parameters is essential for optimizing cutting tool performance.

2.4 Machining Conditions

Machining conditions, such as the type of coolant used, workpiece material properties, and machine - tool rigidity, also play important roles. Coolants help to reduce cutting - zone temperature, flush away chips, and lubricate the cutting interface. Different types of coolants, including water - based emulsions, synthetic fluids, and cutting oils, have varying cooling, lubricating, and anti - corrosion properties. Selecting the appropriate coolant can significantly improve tool life and machining quality.

The properties of the workpiece material, such as hardness, strength, and thermal conductivity, affect the cutting forces and heat generation during machining. For example, machining hard materials like hardened steels requires tools with high wear - resistance and strength. Machine - tool rigidity influences the stability of the machining process. A rigid machine tool can withstand higher cutting forces without vibration, ensuring accurate machining and reducing tool wear caused by chatter.