One of the differentiation that high-performance tools have is the preparation of their cutting edge. Cutting edge preparation influences the Thermo-Mechanic aspects of the cutting process such as the deformation zone, the temperature distribution in the cutting process, the machining process, the chip formation and its flow, the superficial integrity of the job, resistance to wear and microchipping and tool life.

Cutting edge preparation is the process of adapting the surface of the cutting edge for improving the contact zone for machining and the coating process. The cutting-edge preparation could be done by either honing, chamfering or the combination of both to improve the microtopography for the efficient and effective cutting action.

When the process is executed properly it increases the strength of the cutting edge and lifetime of the tool, increases coating productivity minimizes the possibility of built-up-edge formation, and enhances the surface quality of the job.

AXIS mICRO Tools uses a unique proprietary superfinishing process to stabilize the cutting edges. The process is highly reliable, consistent, and repeatable. Application industries benefiting from this process are Aerospace, Medical, mICRO mACHINING, e Mobility, and Consumer Electronics, to name a few and the list is increasing.

Here is a case study which brings succinctly the benefits of superfinishing and edge preparation on the performance of AXIS Tools used in a high precision application in the Aerospace Industry.

Case Study
Machining of Engine Case
Cases are an integral part of the Aircraft Engine that shield and support the parts required for combustion. Hence, they are made from materials that can withstand rapid changes in temperature and are light weighted as well. Heat Resistant Super Alloys (HRSA) such as Inconel and Nickel Alloys, Titanium and Stainless Steels are the materials of choice in such applications.

Drilling Nickel based super alloy is very challenging due to the material properties, operating conditions – large amount of heat generation and its dissipation – and the high component quality requirements.

Here is a case of effective design, appropriate edge preparation, and superfinishing – to enhance coating productivity and chip evacuation ( heat dissipation ) – that has resulted in the outstanding performance of the drill.

Conclusion
Controlled and Consistent micro honing of the cutting edge with a satisfactory texture for subsequent coating process results in strengthening of the cutting edge for improved cutting action, better component quality, and extended tool life.

At AXIS we manufacture Solid Carbide Endmills specially designed to meet the needs of machining hard parts.
Our range includes :
– Ballnose Endmills with ball profile accuracy of ±0.002mm (On demand ±0.0015mm)
– Corner Radius Endmills with radius of ±0.005mm
– Square Endmill with special edge stabalisation treatment

During the machining of hard parts tool wear is very fast because of heat generated during the machining.
Hard part machining requires special edge stabalisation treatment on cutting edges along with suitable coating which can reduce heat generation during the machining.
With our capability of In-house coatings and special capability to ensure controlled edge stabalisation adds an additional feature in our tools to meet exacting applications.

Features :
– Ultrafine Tungsten Carbides
– Optimised geometry
– Controlled edge stabalisation
– High performance PVD Coating to ensure heat resistance

Benefits :
– Long cutting edge retention
– Excellent surface finish
– High dimensional accuracy