The ISO S classification covers materials like high-temperature alloys (HRSA) and titanium alloys, which are widely used in critical industries such as aerospace and energy due to their exceptional thermal hardness and strength. However, these properties also make them challenging to machine compared to traditional steels. To overcome this, tool manufacturers have developed specialized tools and strategies to improve process reliability, stability, and cost-effectiveness when working with these advanced materials.
Today, toolmakers not only provide cutting-edge products but also offer training programs to help manufacturers understand and apply new techniques. They also encourage machine tool builders to rethink outdated methods that may no longer be suitable for modern materials. Machinability is a key concept here, referring to how a material reacts during machining. It involves factors like mechanical forces, chip formation, heat generation, and tool wear. If any of these factors become excessive, the material can be considered difficult to process.
Using the same tools and techniques designed for steel on HRSA or titanium can lead to poor tool life, longer machining times, and lower part quality. While these materials aren’t inherently more difficult to machine, they require different approaches. For instance, instead of reducing cutting parameters, some modern tools are designed to work with higher feed rates and deeper cuts, using fine-grained carbide grades with improved heat resistance and coatings.
Heat management is another crucial aspect. These materials generate and retain significant heat during cutting, often reaching 1100–1300°C. This can cause tool failure and affect part quality. One solution is using sharp tools that cut more efficiently, reducing heat generation. However, this requires machines with sufficient power and stability.
Strain hardening and precipitation hardening further complicate processing. These phenomena cause the material to become harder during machining, making it more challenging to cut. The goal is to minimize passes by using deeper cuts when possible, though balancing aggressiveness with control is essential to avoid vibration and poor surface finish.
Reliability and cost remain top priorities. While technical challenges are largely solved, the real focus is on achieving consistent results within budget and time constraints. Tools and parameters must be optimized to maximize productivity. For example, increasing cutting speed and depth of cut improves throughput, while high-pressure coolant systems can boost efficiency significantly.
Tool life should also be evaluated differently. Instead of just measuring minutes until replacement, the cost per part and the number of parts produced per tool are more relevant metrics. In high-cost applications, even a shorter tool life might be acceptable if it leads to faster production.
In conclusion, the key to leveraging new metal-cutting technologies lies in understanding how best to apply them. As materials evolve, so do the tools and strategies needed to machine them effectively. Manufacturers benefit from staying informed about the latest tools and the expertise of toolmakers.
Continuous innovation remains central. From early stainless steels to today’s high-performance superalloys, the development of materials has driven the need for better cutting solutions. Companies like Seco have dedicated teams to develop new carbides, geometries, and cooling systems to enhance productivity and precision.
For example, Seco’s CS100 sialon grades are ideal for high-speed machining, while CBN170 offers excellent performance for finishing nickel-based superalloys. Their HPDC coolant systems improve chip control and allow higher cutting speeds. By combining advanced tooling with optimized strategies, manufacturers can achieve greater efficiency and quality when working with difficult-to-machine materials.
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