Making special tools-Custom cutting tool

The process of making special (custom) cutting tools involves several precise steps that ensure the tool meets specific machining requirements. Here’s a streamlined version of the process:

1. Requirement Analysis

• Understand customer needs: material to be cut, shape, tolerance, surface finish, machine type.

• Choose tool type: end mill, drill, reamer, form tool, etc.

2. Design & Simulation

• CAD Design: Use CAD software (like SolidWorks or AutoCAD) to draw the geometry of the cutting tool.

• Simulation (CAM): Simulate tool performance using CAM software to validate cutting paths, stress, chip flow, and wear zones.

3. Material Selection

• Choose the appropriate carbide grade or other materials (e.g., HSS, cermet, PCD).

• Consider hardness, toughness, and heat resistance.

4. Blank Preparation

• Cut or grind raw material rods (e.g., carbide rods) to required size.

• Perform stress-relief heat treatment (if needed).

5. Precision Grinding / CNC Tool Grinding

• Use CNC tool grinding machines (e.g., ANCA, Walter, Rollomatic) to shape the cutting edges.

• Apply high-precision grinding for flutes, angles, reliefs, and special forms.

6. Quality Control & Inspection

• Check tool geometry with tool presetters, optical comparators, or laser measurement systems.

• Inspect for:

• Diameter tolerance

• Helix angle

• Surface finish

• Edge sharpness

7. Coating (Optional but Common)

• Apply coatings like TiAlN, TiN, AlCrN, etc. via PVD or CVD.

• Enhances wear resistance, heat resistance, and tool life.

8. Laser Marking / Labeling

• Mark tool specs, brand, or serial number using a laser marking machine.

9. Final Inspection & Packaging

• Perform final QC checks.

• Pack the tool in anti-corrosive cases or tubes for delivery.

Summary Flowchart:

1. Requirement Analysis

2. CAD Design & Simulation

3. Material Selection

4. Blank Prep

5. CNC Grinding

6. Inspection

7. Coating

8. Laser Marking

9. Final QC & Packaging