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How to prevent tool wear and breakage

Precision CNC machining tools are mainly used for high-precision, high-speed heavy metal drilling or forming rough machining, all of which can cause damage to the machine tool in different ways. Although CNC machine tools were originally designed for long-term processing of heavy materials, improper maintenance can lead to severe tool wear. 

Prevent wear and tear of CNC cutting tools:

Choose the appropriate tool material:

Choose high-quality materials, such as hard alloys, which are very suitable for cutting steel and alloys; High speed steel (HSS) is suitable for softer materials.

Choosing the appropriate tool coating, such as titanium nitride (TiN), titanium carbonitride (TiCN), or aluminum oxide (Al ₂ O3), helps maintain suitable temperature conditions while reducing friction, thereby extending the service life of CNC tools.

Optimizing tool geometry: Optimizing tool geometry is crucial as it helps reduce friction. Factors such as front angle, back angle, and chip breaker design help control chips and evenly distribute stress.

For milling machining, groove changing tools can efficiently discharge chips and reduce vibration, thereby further protecting the tool.

Optimize cutting conditions:

After processing the parts and their geometric shapes, it is necessary to adjust the machining conditions to achieve the best machining effect. For example, if the tool speed is too fast, it will cause overheating, while if the speed is too slow, it will cause friction, so it is necessary to find a suitable balance point. Cutting too deep can lead to mechanical failure, while cutting too shallow can cause friction.

Operate the machine according to the specifications in the manufacturer's manual, and then make fine adjustments based on the processing material. In addition, you also need to pay attention to effective chip removal to avoid repeated cutting of abrasive chips. Blocked chips can cause temperature rise and tool deflection, which may lead to tool fracture.

Appropriate cooling and lubrication:

Frequent cooling is crucial for obtaining optimal machining conditions and extending the service life of CNC tools. During the machining process, the use of oil-based and water-based coolant can reduce the heat and friction generated by cutting tools.

There are various cooling methods, such as immersion cooling for general machining, atomization cooling for dry machining, and high-pressure deep coolant for heavy or deep cutting machining. In addition, the delivery method of coolant is also crucial, such as atomization, immersion, and micro lubrication (MQL) systems, which help to directly deliver coolant to the contact surface between chips and tools.

Maintaining the quality of coolant is equally important as using the appropriate coolant, therefore, it is necessary to regularly monitor the pH value, filters, contaminants, and concentration of the coolant to ensure optimal efficiency.

Implement tool and machine tool monitoring:

Real time monitoring of various parameters, such as force, spindle load, temperature, acoustic emission, and vibration. Modern monitoring systems can also issue alerts to users before any major malfunctions occur.

Acoustic emission monitoring sensors can also be used. These sensors help detect stress wear or blade breakage. Different embedded sensors and advanced machine learning models help identify wear trends and predict the end of tool life in advance.

High stability fixtures and vibration reduction:

When cutting heavy materials, severe vibrations are usually generated, which may lead to increased tool wear. Using precision tool holders, heat shrink clamps, or hydraulic clamps can help you minimize these vibrations to the greatest extent possible. You should pay attention to loose clamping, as this may cause uneven tool wear, vibration, and even sudden failure.

Ensuring the correct alignment of the machine tool is also crucial, so please regularly inspect the machine tool and ensure calibration to reduce tool stress and wear.

Inspection and maintenance:

Cutting tools should be kept clean and sharp, so they must be cleaned with solvents or ultrasonic cleaning machines after each use, and a soft bristled brush must be used to protect the coating and blade while keeping the tool clean. In addition, grinding or re grinding should be carried out before the tool reaches the failure threshold.

After use, the machine should be stored in a dry and orderly environment. The best way to store tools is usually to use the original toolbox or protective rack. You can also use desiccant packs and be sure to avoid any collisions with the edges of the tool.

Operator skills and training:

Last but not least, the skills of operators in handling various situations and successfully completing machining are crucial for extending the service life of CNC machine tools. Operators should receive sufficient training and master knowledge of machining principles, tool characteristics, and troubleshooting.

In addition, the work area should be kept orderly, and a dedicated person should be designated to be responsible for the distribution, tracking, and grinding process of cutting tools, in order to better manage and protect them, especially in large factories. Finally, it is essential to ensure that all operators strictly adhere to all safety regulations and manufacturer recommended operating procedures.

Advanced technologies for improving tool life:

The use of cycloidal milling technology can reduce meshing and heat accumulation, which is particularly useful in cavity machining and slotting projects.

Methods such as electrical discharge machining or electrochemical grinding can help eliminate mechanical wear of machines.

Using high-speed machining (HSM) strategy and adaptive tool path to reduce chip load, while low-temperature cooling can help you adopt thermal strategy, thereby extending the service life of cutting tools.