products, and shorter tool life. This article explains the causes, measurement methods, maintenance methods, and countermeasures for this issue.
The causes of deterioration in cutting tool sharpness include wear during cutting, thermal effects, inappropriate machining conditions, excessive load, material inhomogeneity, and inappropriate selection of cutting edge material.
Deterioration in sharpness increases friction and heat, placing a load on the tool and leading to tool wear and anomalies. Additionally, vibrations during cutting and increased machining time can accelerate tool wear and anomalies.
Cutting edge sharpness is generally assessed visually or by touch, but more precise measurements require specialized instruments. Typical measuring instruments include optical microscopes, shape measuring devices, force meters, and acoustic measuring devices.
Instruments needed for measuring sharpness include a light source, optics, scales, and slides. The method of use varies depending on the type of measuring instrument but generally involves fixing the tool and contacting it with the measuring instrument for measurement.
The material of the cutting edge varies depending on the type of material being cut. If the edge material is not appropriately selected, tool wear and anomalies may occur. Especially in high-speed cutting, high wear resistance is required, necessitating the use of superior materials.
Commonly used cutting edge materials include high-speed steel (HSS), ceramic, CBN (cubic boron nitride), diamond, and stainless steel. Each material has its unique properties. For example, HSS maintains high wear resistance even at high temperatures, and ceramic has high hardness and excellent heat resistance.
Selecting the cutting edge material should be based on the cutting conditions, considering the type of material being cut, hardness, whether heat treatment is applied, cutting speed, machining accuracy, and material abrasiveness. Choosing the appropriate cutting edge material is crucial.
By implementing these measures, it is possible to prevent tool wear and anomalies, improve manufacturing efficiency, and enhance product quality. It is also crucial to anticipate and prevent issues in the manufacturing environment. For example, by predicting the lifespan of tools and planning replacement timing, sudden stops or production line downtimes can be avoided. Therefore, active monitoring of cutting tool conditions and preventative maintenance are essential.
To prevent tool wear and anomalies caused by the deterioration of the cutting edge's sharpness, it is vital to practice accurate measurement and maintenance methods and set appropriate cutting conditions. Additionally, continually acquiring the latest information and technology, along with preventative maintenance, can lead to improved productivity and cost reduction in the manufacturing environment.
This article discussed measures against tool wear and anomalies caused by the deterioration of the cutting edge's sharpness, including methods for measuring and maintaining sharpness, countermeasures when sharpness deteriorates, and reviewing cutting edge materials as a preventative strategy.
The measuring instruments mentioned, such as optical microscopes, shape measuring devices, force meters, and acoustic measuring devices, are highly convenient for research or experimental purposes due to their precision. However, since many of these instruments assume the tool will be removed for use, their application might be challenging in an active production line. When considering their use, it is important to select measuring instruments and methods appropriate for the application. By managing and monitoring tools, aim to improve the production efficiency of your factory.
