Micro milling of fused silica using picosecond laser shaped single crystal

“You need high pressure coolant because of the super-heated steam in the shear zone,” Penkert explains. “It’s very important to protect the carbide tools from heat because there can be a softening effect where the cobalt binder weakens and your cutting process is no longer secure.”

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“At higher radial engagements, the insert is cutting the material for a longer time which creates more heat at the cutting zone,” He says. “The heat will not transfer into the titanium chips as is the case when milling steels so controlling the heat is critical. Lower cutter speeds at higher radial engagements is good practice. At lower radial engagements, higher cutting speeds can be achieved.”

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The KCSM40 grade has an advance cobalt binder that provides very high thermal fatigue resistance. In addition to the new material substrate Kennametal’s proprietary AlTiN/TiN coating enhances wear resistance at the cutting edge.

Kennametal has developed a new carbide grade, KCSM40, said to greatly enhance cutting of titanium Ti6Al4V and other high tensile strength alloys.

Scott Etling, director of global product management, for indexable milling at Kennametal, explains the radial engagement of the milling cutter to the workpiece is one key component when optimising the cutting speed.

New York, July 06, 2023 (GLOBE NEWSWIRE) -- Reportlinker.com announces the release of the report "Cutting Tools Market - Global Outlook & Forecast 2023-2028" - https://www.reportlinker.com/p06461218/?utm_source=GNW Consumers in countries like France, Germany, Italy, and the UK consider DIY activities a significant hobby. The concept is also gaining popularity in developing economies such as India, Brazil, and South Africa. The growing interest among consumers in undertaking their projects and maintaining a sustainable environment has increased the demand for D.I.Y products such as cutting tools. During the pandemic, many people turned to DIY activities to relieve stress and take care of tasks to reduce costs while staying indoors. The concept of D.I.Y is well-adopted in Western countries, with most American regions contributing to nearly 81% of the market share in the D.I.Y industry. This trend is expected to continue during the forecast period. The surge in the D.I.Y industry is projected to grow due to the high penetration of media presence, including television, social media, and videos, which have helped recreate home improvement projects. Western countries like North America and Canada actively engage in D.I.Y activities. Additionally, many retail stores like supermarkets and hypermarkets have enabled significant growth for many vendors in the D.I.Y segment.Rising Usage of Cutting Tools In General Manufacturing IndustriesCutting tools are crucial in manufacturing, particularly in producing general machinery, automobiles, aviation and aerospace, energy, medical equipment, rail transit, molds, machine tools, and other industries. The automotive manufacturing process heavily relies on cutting tools as they are one of the key components of the process. The traditional procedures have been replaced with new techniques like high-speed cutting, dry machining, hard machining, and advanced cutting technology.The automotive sector has significantly shifted towards using professional tools such as Carbide Cutters. This transformation is driven by the need for high product quality and precision, which is required to produce high-value parts. The industrial circle has gradually moved from traditional machining to high-performance cutting tools that provide greater efficiency and accuracy. Furthermore, due to machinery and equipment automation and the growing need for high-performance, high-precision machining equipment has become essential to industry growth. As a result, the demand for high-efficiency and performance-cutting tools is increasing. Such factors drive the development of new cutting technologies in the cutting tools market.SEGMENTATION ANALYSISINSIGHTS BY TOOL TYPEThe dominance of the indexable tool type segment in the global cutting tools market in 2022 can be attributed to its modern turning operations. This has displaced previous common tool types, such as HSS, brazed-carbide, and custom form tools, before the widespread use of CNC machines. Indexable turning tools, when used in conjunction with the multiple-axis motion of a CNC machine tool, make it easier to create complex shapes, eliminating the need for dedicated turning tools. However, solid round tools are experiencing high growth rates in the global cutting tools market due to their ability to cover all application types within solid carbide drilling, milling, HSS tapping, reaming, and threading. Each solid round tool is designed to meet the requirements of high quality, precision, and maximum productivity, allowing for optimal machining processes.Segmentation by Tool Type• Indexable• Solid RoundINSIGHTS BY PRODUCT TYPEThe global cutting tools market by product segments as groovers, reamers, milling cutters, drills, and others. In 2022, the Groover product type dominated the industry. These tools are highly used with lathes to cut channels on the end of a workpiece or into an existing bore. Groovers are also utilized for various applications, including creating recesses for retaining rings and necking workpieces to ensure a clean fit when mating parts. Additionally, a grooving tool is a cutting tool that removes material to form grooves, channels, or other cross-sectional shapes on the workpiece. A groove may be cut with an end mill having one fixed cutter and another moveable cutter placed at each side. Such tools are also called profile mills when they produce linear cuts along the length of the item being milled. Grooving inserts can be made from carbide, ceramic, diamond, or PCD (polycrystalline cubic boron nitride). These inserts are mainly employed by metalworking industries like aerospace & defense equipment manufacturers. Still, non-metal manufacturing companies such as medical device makers use them for grooving medical-grade plastic parts.Segmentation by Product• Groovers• Reamers• Milling Cutters• Drills• OthersINSIGHTS BY MATERIAL TYPEThe cemented carbide material type segment dominated the global cutting tools market and was valued at over USD 3.2 billion in 2022. This market is highly fragmented and consists of many companies operating on both global and regional levels. This indicates that manufacturers of cutting tools possess significant bargaining power over suppliers. Cemented carbide tools are primarily used for high-precision work involving greater shape, size, and structure complexity. However, specialized cutting tools are more cost-effective and efficient for specific tasks. The APAC and North American regions are expected to have the largest share in the global cemented carbide industry. Vendors in these areas are anticipated to benefit from abundant raw material availability and will provide a competitive advantage to vendors regarding the selling price. The high availability of other raw materials, such as steel, in countries like China, India, and the U.S., is also expected to lead to high growth rates for high-speed steel (HSS) tools. This is expected to enable vendors to further enhance their profit margins by maintaining good supplier-vendor relationships.Segmentation by Material Type• Cemented Carbide• High-Speed Steel• Ceramics• CBN• OthersINSIGHTS BY END-USERThe automotive industry is the largest end-user segment in the global cutting tools market. Drilling and fastening tools are the primary tools for tightening fasteners, engine mounting, and other joint works. Sanders and angle grinders are used for smoothening and polishing the vehicle parts and chassis. With the global electric vehicles market growing at almost 60% annually, expansion and increased production facilities are expected to increase the demand for cutting tools. This can be more prominent in countries such as China, Japan, the US, and Western Europe, where the production of EVs is more likely to accelerate during the forecast period.Segmentation by End-User• Automotive• General Manufacturing• Oil & Gas• Aerospace & Defense• Electronic & Electricals• Medical• OthersINSIGHTS BY DISTRIBUTION CHANNELThe offline distribution channel had the highest global cutting tools market in 2022. Factors such as the broader reach in areas that lack better connectivity and high consumer trust associated with touching and experiencing the quality of products are driving the growth of this segment. Although the online segment holds a relatively lower market share, it is expected to grow faster than offline distribution channels.Segmentation by Distribution Channel• Offline• OnlineGEOGRAPHICAL ANALYSISAPAC was the largest cutting tools market in 2022, as it is home to several industries, including manufacturing, services, automobiles, and electrical. This consequently increases the need for a unique assortment of cutting tools with accuracy in performance. While Japan and South Korea are major manufacturers and exporters of electrical appliances and automobiles, Singapore dominates with its excellent construction facilities. Furthermore, the increasing purchasing power of consumers and the rising DIY culture among young and experienced consumers are driving the regional residential tools market, including cutting tools. Further, the comparatively lower dominance of the cutting tools owing to the less awareness and operating knowledge in countries like India and China is a natural boost for cutting tool vendors.Segmentation by Geography• APACo Chinao Japano Indiao Australiao South Korea• North Americao The U.S.o Canada• Europeo Germanyo Franceo The U.K.o Italyo Spain• Middle East & Africao Saudi Arabiao South Africao UAE• Latin Americao Brazilo Mexicoo ArgentinaVENDOR LANDSCAPEThe global cutting tools market is characterized by low market concentration and high competition among the major players. The present scenario drives vendors to alter and refine their unique value propositions to achieve a strong market presence. Currently, the cutting tools market is highly fragmented and dominated by vendors such as Kennametal Inc, OGS Corporation, and Iscar Ltd, among others, alongside numerous domestic tool manufacturers that manufacture cutting tools as per the local demands and regulations.Key Company Profiles• Kennametal Inc.• OSG Corporation• Iscar LtdOther Prominent Vendors• Mapal• Makita Corporation• Robert Bosch• Stanley Black & Decker• Kelin Tools• ICS Cutting Tools Inc• Snap-on Incorporated• OTTO BAIER GmbH• Hilti Corporation• Sandvik AG• Ingersoll Cutting Tools• FRASIA SA• KYOCERA• J SCHNEEBERGER Maschinen AG• VOLLMER• CERATIZIT Group• HIKOKIKEY QUESTIONS ANSWERED:1. How big is the global cutting tools market?2. What is the growth rate of the global cutting tools market?3. Which region dominates the global cutting tools market share?4. Who are the key players in the global cutting tools market?5. What are the significant trends in the cutting tools market?Read the full report: https://www.reportlinker.com/p06461218/?utm_source=GNWAbout ReportlinkerReportLinker is an award-winning market research solution. Reportlinker finds and organizes the latest industry data so you get all the market research you need - instantly, in one place.__________________________

Kennametal has launched a new insert grade named KCSM40, targeted to machine high temperature titanium alloys widely used for aerospace applications. Ed Hill spoke to the cutting tool specialist about its products designed for difficult-to-machine materials. Due to production rates ramping up for new aircraft, particularly in the commercial market, developers of cutting tools are constantly under pressure to deliver faster and more efficient metal removal rates. In an industry that often uses difficult to machine materials such as titanium this throws up some demanding challenges. Kennametal has developed a new carbide grade, KCSM40, said to greatly enhance cutting of titanium Ti6Al4V and other high tensile strength alloys. Werner Penkert, Kennametal, manager aerospace solutions engineering EMEA, says: This new grade is a development from our carbide grades, KC725M and X500 which are well-known for their reliable performance and long tool life. It increases speed by around 30% but still with excellent tool life.” The KCSM40 grade has an advance cobalt binder that provides very high thermal fatigue resistance. In addition to the new material substrate Kennametal’s proprietary AlTiN/TiN coating enhances wear resistance at the cutting edge. Cutting edges still performing well after 100 minutes of machining Ti6Al4V at 47m/minute with a .0067ipt chip load More speed In trials, the target cutting speed for KCSM40 in titanium Ti6Al4V was 175 SFM (53m/min) while achieving greater than 20 cubic inches per minute (327cm³/min) metal removal rate for 60 minutes. Not only has KCSM40 achieved this, but results of milling titanium at speeds up to 270 SFM (85m/min) at a lower radial depth of cut have been achieved. Scott Etling, director of global product management, for indexable milling at Kennametal, explains the radial engagement of the milling cutter to the workpiece is one key component when optimising the cutting speed. “At higher radial engagements, the insert is cutting the material for a longer time which creates more heat at the cutting zone,” He says. “The heat will not transfer into the titanium chips as is the case when milling steels so controlling the heat is critical. Lower cutter speeds at higher radial engagements is good practice. At lower radial engagements, higher cutting speeds can be achieved.” Kennametal has carried out extensive trials using a new HARVI Ultra helical milling platform to mount the new inserts. It achieved over 100 minutes of tool life running at 155 SFM (47m/min) with a 0.0067ipt (0.12mm/tooth) chip load. The radial depth of cut was 25mm and the axial depth of cut was 76mm. “The edge condition on the KCSM40 grade insert still looked great,” states Etling. “And we are getting many other fantastic results. In one face milling operation on a hardened steel wear plate the number of passes was reduced from 234 to just 22. I am very excited how KCSM40 will benefit our customers.” Demand for higher metal removal rates was the main driver for Kennametal to develop the new grade. “Cycle time is very important because all aircraft builders are under pressure to deliver higher volumes,” notes Penkert. “When companies invest in new machine tools, they want to process the parts much faster. However, customers also require secure processes with other developments such as increased automation. “These days it is rare that a machine operator will be constantly monitoring a machine. Machine tools also use high pressure coolant so it’s very difficult to see what is happening at the cutting edge. A secure manufacturing process is essential because of the value of the parts being produced and the value of the machines they are being made on.” Kennametal has carried out extensive trials using a new Harvi Ultra helical milling platform Heat and steam Titanium poses particular challenges when being cut because of the high temperatures generated at the shear zone. Coolant can vaporise even before it makes contact with the workpiece. “You need high pressure coolant because of the super-heated steam in the shear zone,” Penkert explains. “It’s very important to protect the carbide tools from heat because there can be a softening effect where the cobalt binder weakens and your cutting process is no longer secure.” Kennametal carries out many trials with it customers to help them come up with efficient cutting strategies. “We have good data about our cutters’ tool life but you always have to judge what is happening with an application in the real world,” Penkert continues. “We have to consider what material is being cut, the stability of the machine tool, the clamping, the lubricant etc. All these variations have to be taken into account including the part being made itself. Is it thick and stable or thin and instable? “Our data is a starting point but then we have to prove out strategies in a manufacturing cell. Here we can monitor the wear, so after a number of minutes of cutting we have an accurate idea of the wear rate which occurs in that application.” Along with its metalcutting products used for machining high grade alloys, Kennametal has also developed a range of cutting tools for the increasing amounts of composite materials used in aerospace. “We anticipate that composites will continue to grow in aerospace,” says Penkert. Kennametal has a number of products for composite machining. These include trimming tools, which mill the outside edge of a part or tools that drill and then mill from the inside of the part. We also have tools for contour milling of CFRP. “We are also involved in the assembly of the aircraft with hole drilling. This can involve drilling through CFRP/aluminium or CFRP/titanium stacks. This can be difficult because you have to prevent burrs on the entry and exit of holes, avoid delamination and fibre breakout and we have to provide a geometry that can deal with these different materials in one operation. Another factor is composite materials are highly abrasive. In these circumstances we find PCD is a very good cutting grade or diamond film coated drills.” More Kennametal tools used for aerospace applications such as turbines Adding advances The aerospace sector is an important market for Kennametal and its tool development as the advanced engineering involved always poses new machining challenges. An example of this is the tooling specialist’s membership of the Advanced Manufacturing Research Centre (AMRC) in Sheffield, where along with aerospace OEMs and other industry stakeholders machining and materials research is carried out for aerospace and other high-value manufacturing sectors. Werner Penkert, Kennametal, manager aerospace and defence solutions EMEA “We work very intensely with the OEMs and tier 1 companies on projects, along with our application engineers who help all our customers in the industry. Also, there is always the demand created by new and improved machine tools. Manufacturers and their customers want turnkey projects which includes us providing solutions. In these situations, there is a lot of collaboration between the cutting tool supplier, the machine tool builder, the fixture manufacturer and the end user. Our specialists work with all involved to support each other.” And Penkert believes there are still possibilities for cutting tool performance to be enhanced. “Improvements can be made to the carbide grade, the substrate and the coatings. And there are ongoing developments with machine tools which means there is always a research partnership needed between us and the manufacturers. When a machine tool comes along with new performance capabilities, this allows the cutting tool developers to create products that match the improved performance of the machine tool.” www.kennametal.com

“These days it is rare that a machine operator will be constantly monitoring a machine. Machine tools also use high pressure coolant so it’s very difficult to see what is happening at the cutting edge. A secure manufacturing process is essential because of the value of the parts being produced and the value of the machines they are being made on.”

“We work very intensely with the OEMs and tier 1 companies on projects, along with our application engineers who help all our customers in the industry. Also, there is always the demand created by new and improved machine tools. Manufacturers and their customers want turnkey projects which includes us providing solutions. In these situations, there is a lot of collaboration between the cutting tool supplier, the machine tool builder, the fixture manufacturer and the end user. Our specialists work with all involved to support each other.”

“The edge condition on the KCSM40 grade insert still looked great,” states Etling. “And we are getting many other fantastic results. In one face milling operation on a hardened steel wear plate the number of passes was reduced from 234 to just 22. I am very excited how KCSM40 will benefit our customers.”

“Cycle time is very important because all aircraft builders are under pressure to deliver higher volumes,” notes Penkert. “When companies invest in new machine tools, they want to process the parts much faster. However, customers also require secure processes with other developments such as increased automation.

Titanium poses particular challenges when being cut because of the high temperatures generated at the shear zone. Coolant can vaporise even before it makes contact with the workpiece.

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ANT Industries, a leading manufacturer of aero engine and gas turbine components in Atherstone, Warwickshire, has announced a significant milestone in its commitment to quality and excellence.

“We have good data about our cutters’ tool life but you always have to judge what is happening with an application in the real world,” Penkert continues. “We have to consider what material is being cut, the stability of the machine tool, the clamping, the lubricant etc. All these variations have to be taken into account including the part being made itself. Is it thick and stable or thin and instable?

Werner Penkert, Kennametal, manager aerospace solutions engineering EMEA, says: This new grade is a development from our carbide grades, KC725M and X500 which are well-known for their reliable performance and long tool life. It increases speed by around 30% but still with excellent tool life.”

“Our data is a starting point but then we have to prove out strategies in a manufacturing cell. Here we can monitor the wear, so after a number of minutes of cutting we have an accurate idea of the wear rate which occurs in that application.”

Kennametal has carried out extensive trials using a new HARVI Ultra helical milling platform to mount the new inserts. It achieved over 100 minutes of tool life running at 155 SFM (47m/min) with a 0.0067ipt (0.12mm/tooth) chip load. The radial depth of cut was 25mm and the axial depth of cut was 76mm.

Due to production rates ramping up for new aircraft, particularly in the commercial market, developers of cutting tools are constantly under pressure to deliver faster and more efficient metal removal rates. In an industry that often uses difficult to machine materials such as titanium this throws up some demanding challenges.

“We anticipate that composites will continue to grow in aerospace,” says Penkert. Kennametal has a number of products for composite machining. These include trimming tools, which mill the outside edge of a part or tools that drill and then mill from the inside of the part. We also have tools for contour milling of CFRP.

“We are also involved in the assembly of the aircraft with hole drilling. This can involve drilling through CFRP/aluminium or CFRP/titanium stacks. This can be difficult because you have to prevent burrs on the entry and exit of holes, avoid delamination and fibre breakout and we have to provide a geometry that can deal with these different materials in one operation. Another factor is composite materials are highly abrasive. In these circumstances we find PCD is a very good cutting grade or diamond film coated drills.”

In trials, the target cutting speed for KCSM40 in titanium Ti6Al4V was 175 SFM (53m/min) while achieving greater than 20 cubic inches per minute (327cm³/min) metal removal rate for 60 minutes. Not only has KCSM40 achieved this, but results of milling titanium at speeds up to 270 SFM (85m/min) at a lower radial depth of cut have been achieved.

“Improvements can be made to the carbide grade, the substrate and the coatings. And there are ongoing developments with machine tools which means there is always a research partnership needed between us and the manufacturers. When a machine tool comes along with new performance capabilities, this allows the cutting tool developers to create products that match the improved performance of the machine tool.”

Kennametal carries out many trials with it customers to help them come up with efficient cutting strategies.

Kennametal has launched a new insert grade named KCSM40, targeted to machine high temperature titanium alloys widely used for aerospace applications. Ed Hill spoke to the cutting tool specialist about its products designed for difficult-to-machine materials.

Along with its metalcutting products used for machining high grade alloys, Kennametal has also developed a range of cutting tools for the increasing amounts of composite materials used in aerospace.

Cutting edges still performing well after 100 minutes of machining Ti6Al4V at 47m/minute with a .0067ipt chip load

The aerospace sector is an important market for Kennametal and its tool development as the advanced engineering involved always poses new machining challenges. An example of this is the tooling specialist’s membership of the Advanced Manufacturing Research Centre (AMRC) in Sheffield, where along with aerospace OEMs and other industry stakeholders machining and materials research is carried out for aerospace and other high-value manufacturing sectors.