3 ways to extend machine tool life

Many automotive and aerospace firms are under significant pressures to cut costs, but improve the efficiency of their processes. Yet the rigorous nature of manufacturing takes its toll on the machine tools used, which may require purchasing of new equipment.

The difficulty here is that machine tools aren’t cheap. For example, a 12mm PCD cutter can cost anywhere between £300-£500. CNC machines can cost thousands of pounds. So it may be a case of trying to find ways to extend tool life to avoid having to spend on new machines.

That’s why we’ve come up with 3 ways to help you extend the life of your machine tools. This includes coating tools with cutting fluid, optimising cutting entry and upgrading software. 

Coat your tools

A critical element to extending tool life is ensuring machine tools are properly lubricated with cutting fluid i.e. oil, coolant.

For example, the heat generated when the cutting tool is in action can reach temperatures high enough to produce deformations in the cutting tool as well as the material being machined. By applying coolant to the cutting tool, you can reduce the chances of significant wear and tear, prolonging tool life.

You also need to think about the specific cutting fluid to use. For example, water-soluble cutting fluids are very effecting in removing heat. However, using a water-based cutting fluid can potentially cause rust formation. That’s why you need to ensure that you use a cutting fluid that contains a rust inhibitor, reducing the chances of the formation of rust on the machine tool.

Optimise your cut entry

If not properly planned, the initial entry of the cutting tool into the material can damage the tool and affect the surface finish of the material. For example, a poor entry can lead to a chip in the material, reducing the quality of the part being machined.

That’s why you should consider using a spiral motion or arc into the cut when making the initial entry into the material. This is particularly effective in improving tool life when used on metals such as stainless steel.

Upgrading software 

Finally, tool life can be extended by upgrading your software. Although it may sound counter-intuitive to spend money when trying to cut costs, making an investment in improving your manufacturing process can have significant cost savings in the long term.

For example, ICAM’s SmartCUT software solution is able to detect positioning (i.e. RAPID) that cuts into the in-process material, both warning the NC programmer and automatically slowing down the feed-rate to prevent the tool from breaking.

SmartCUT also helps to prevent ‘air-cuts’ by conducting simulations to assess when the tool is not in use with the material, eliminating non-cutting feed motions. 

Essentially, SmartCUT is able to intelligently detect the optimal interaction between the cutting tool and material, helping to extend tool life. 

In summary, aerospace and automotive firms face significant pressures to cut costs but finding areas within the design and manufacturing process to reduce costs can be difficult.

Yet, these organisations can achieve significant cost savings by extending tool life. This can be done by;

• Coating machine tools with sufficient lubrication, ensuring the heat generated doesn’t damage the tool or the surface material
• Optimising cut entry also helps to reduce the chances of the tool breaking, helping to maintain the integrity of the part being machined
• Upgrading to the right software solution can help to prolong tool life while increasing the efficiency of the manufacturing process.