The Evolution of Cutting Tool Materials: From High Carbon Steel to Cemented Carbide and Beyond.
Cutting tools have undergone a remarkable transformation over the years, especially in the field of machining. In the 1800s, high carbon steel and alloy steels were the primary materials used for cutting tools. These early tools had limitations in terms of durability and performance, especially when subjected to high temperatures and heavy loads. However, a major breakthrough came with the accidental development of Mushet Steel, which led to the creation of high-speed steel (HSS) around 1915. This innovation allowed for faster cutting speeds and longer tool life, marking a significant leap in tool technology.
By the 1930s, the introduction of cemented carbide revolutionized the industry once again. Also known as sintered carbide or tungsten carbide, this material consists of hard carbide particles held together by a metallic binder. Initially, these tools were brazed onto their bodies, but the industry soon shifted toward indexable inserts. These inserts are manufactured by pressing a slurry of carbide into a die, then undergoing a high-temperature sintering process to increase density, hardness, and strength. Some inserts are also ground to achieve precise dimensions, while others are coated with thin layers to improve wear resistance and performance.
Compared to HSS tools, cemented carbide tools offer superior heat and wear resistance, allowing for higher cutting speeds and feeds, which leads to greater productivity and cost savings. However, they are more brittle and require better machine setups, such as high-quality spindles and fixtures. As a result, they are commonly used in CNC machines, whereas HSS tools are still preferred in manual or less demanding applications. Another alternative is cermet, a material similar to carbide but with titanium-based hard particles. It provides excellent surface finishes and wear resistance but is not suitable for high-stress conditions or deep cuts.
Ceramic tools are ideal for machining difficult-to-cut materials like hardened steel, cast iron, and super alloys due to their ability to withstand extreme heat. CBN (polycrystalline cubic boron nitride) is an extremely expensive option used mainly for machining hardened steels and gray cast iron. It's often bonded to a carbide substrate in the form of inserts or layers. PCD (polycrystalline diamond) is used for non-ferrous materials like aluminum, but it cannot be used on steel or cast iron because it tends to degrade at high temperatures.
In the past, cutting tools required frequent resharpening or replacement when worn out. The development of indexable inserts changed that—now, worn-out inserts can simply be replaced without the need for regrinding or reshaping. Their tight tolerances and consistent geometry make them ideal for use in CNC machines, where precision and efficiency are critical. Today, indexable inserts made from a variety of advanced materials are at the core of modern machining practices.
In summary, the evolution of cutting tool materials has played a crucial role in advancing machining technology. From the early days of high carbon steel and HSS to the development of cast alloys, cemented carbides, cermet, ceramics, CBN, and PCD, each advancement has contributed to faster, more precise, and more efficient machining. With the widespread use of indexable inserts, the industry continues to move toward higher productivity, reduced downtime, and improved part quality. This ongoing progress ensures that cutting tools remain a vital component in modern manufacturing processes.
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