CNC Cutting Tools Revolution: Advanced Applications and Industry Trends

Driven by advancements in electronics, information technology, materials science, and other high-tech fields, traditional manufacturing techniques are undergoing profound transformation.

They are rapidly evolving toward digital manufacturing technologies.

Numerical control (NC) machining technology can significantly boost production efficiency.

It has gained widespread adoption in manufacturing, driving continuous iteration and upgrades in NC tool manufacturing and application technologies.

A growing array of high-speed, high-efficiency, flexible, multi-functional, and eco-friendly CNC cutting tools and application technologies are emerging to meet the demands of modern cutting techniques.

These advancements feature hard cutting, dry cutting, and high-speed, high-efficiency machining.

They are driving comprehensive improvements in cutting technology and have become key to CNC machining.

CNC cutting tools have evolved into high-value-added, high-tech products.

They integrate the latest achievements from multidisciplinary fields such as materials science, mechanical manufacturing, industrial automation, and smart manufacturing.

Overview of CNC Cutting Tools

• Definition and Classification of CNC Cutting Tools

CNC cutting tools primarily perform machining operations on CNC machine tools, serving as one of the core components throughout the entire CNC machining process.

As critical consumables in modern mechanical manufacturing, CNC cutting tools encompass not only the cutting inserts directly involved in machining but also essential accessories like tool shanks and tool holders.

These components work in concert to achieve precise material removal from workpieces, meeting diverse machining requirements.

Overall, metal cutting comprises two vital elements: CNC machine tools and CNC cutting tools, which together form the fundamental process equipment for machining.

We can categorize CNC cutting tools into multiple types based on different classification criteria.

(1) By Application

① Turning Tools: Subdivided into external turning tools, internal turning tools, thread turning tools, and grooving tools.

② Milling tools: Face milling cutters (e.g., cylindrical face milling cutters, end mills); end mills capable of both side milling and contour machining; mold milling cutters specifically designed for complex mold cavity machining.

③ Drilling tools: Primarily used for drilling, reaming, and boring operations on workpieces.

④ Boring tools: Categorized into rough boring tools and finish boring tools to meet the machining requirements of hole systems with different precision grades.

⑤Gear cutting tools: Specialized tools for gear production, primarily used for machining the tooth surfaces of various cylindrical gears, bevel gears, and other toothed workpieces.

⑥ Special-purpose tools: Examples include PCB (Printed Circuit Board) tools, which engineers specifically design for printed circuit board machining.

(2) Classification by Material

① High-speed steel tools: Possess good toughness and are easy to sharpen, but are not suitable for high-speed, high-intensity cutting scenarios.

② Carbide tools: Feature high hardness and exceptional wear resistance.

Suitable for high-speed cutting and machining various difficult-to-cut materials such as stainless steel, high-manganese steel, alloy cast iron, and titanium alloys.

③ Ceramic tools: Possess extremely high hardness exceeding cemented carbide, with outstanding wear resistance and heat resistance.

Commonly used for finishing or semi-finishing operations on highly hard materials.

④ Diamond tools: Categorized into natural single-crystal diamond tools, synthetic polycrystalline diamond tools, and sintered diamond tools.

Possess extreme hardness and wear resistance, enabling ultra-thin cutting. They are among the ideal tools for ultra-precision machining.

Currently primarily used for fine cutting of non-ferrous metals and non-metallic materials, unsuitable for ferrous metal processing.

(CBN Tools: Available in solid polycrystalline cubic boron nitride tools and CBN composite inserts.

Their hardness and wear resistance are second only to diamond, enabling roughing and semi-finishing of extremely hard materials like cold-hardened steel and cold-hardened cast iron.

(3) Classification by Structure

① Integral Tools: Manufactured from a single blank, these tools feature simple construction and high rigidity.

They are commonly used for small tools or applications demanding superior overall tool performance.

② Indexable Tools: Employing welded or mechanically clamped connections, mechanically clamped tools further divide into non-indexable and indexable types.

③ Special-purpose tools: Includes composite tools, vibration-damping tools, etc.

Composite tools integrate multiple cutting functions, allowing operators to perform several operations in a single setup.

Vibration-damping tools are specifically designed to address vibration issues that arise during machining with long overhangs.

Their internal structure incorporates special damping materials to ensure tool stability during high-speed cutting, commonly used for machining thin-walled components in aerospace applications.

• Working Principle and Characteristics of CNC Cutting Tools

(1) Working Principle of CNC Cutting Tools

Cutting tool machining is a traditional manufacturing method based on material removal principles.

It uses the relative motion between the tool and the workpiece to remove excess material from the workpiece.

This process serves as the primary manufacturing method for producing core components in high-end equipment.

Through relative motion between the tool and workpiece, the tool penetrates the workpiece, removing excess material in the form of chips.

During this process, the cutting edge of the tool maintains close contact with the workpiece material.

The cutting edge applies pressure, which induces shear deformation in the material.

When the shear stress exceeds the material’s yield strength, it shears off.

(2)Characteristics of CNC Cutting Tools

CNC cutting tools possess a series of characteristics that meet the stringent demands of modern manufacturing.

① In terms of machining accuracy, the high-precision geometric shape and dimensional stability of CNC cutting tools form the foundation for precision machining.

② Regarding surface quality, the sharpness of the cutting edge, surface roughness, and chip evacuation performance of CNC cutting tools directly impact the surface quality of the workpiece.

③ Production Efficiency:

Firstly, the tools’ high-speed cutting capability significantly increases material removal rates per unit time, meeting the demands of large-scale, high-efficiency production rhythms.

Secondly, tool reliability and extended service life reduce frequent tool changes, boosting overall production efficiency.

④ In specialized customization, the importance of CNC cutting tools is increasingly prominent.

In the manufacturing of monolithic titanium alloy blade disks, the material’s difficult-to-machine properties make it challenging to ensure both machining accuracy and efficiency.

However, specialized custom tools, combined with advanced cutting techniques, can overcome the difficulties posed by titanium alloys’ high strength and low thermal conductivity.

This enables the one-time, monolithic machining of complex blade disk structures, driving technological advancement in the aerospace industry.

Key Industry Applications of CNC Cutting Tools

• Aerospace Industry

(1) Requirements for CNC Cutting Tools in Aerospace

First, ultra-high precision demands.

Component dimensional accuracy and geometric tolerances are extremely stringent.

Critical parts typically require profile tolerances controlled within ±0.05mm, with surface roughness values (Ra) reaching 0.4–0.8μm.

Second, complex structure machining capability. Part structures are increasingly intricate, featuring numerous thin walls, deep cavities, narrow slots, and complex curved surfaces.

This is especially true for aircraft structural components, such as wing spars and fuselage frames.

These components are often large, thin-walled structures with high material-removal rates and are prone to deformation.

Third, Adaptability to Difficult-to-Machine Materials.

The aerospace sector extensively utilizes difficult-to-machine materials such as titanium alloys, nickel-based alloys, and carbon fiber composites.

These materials exhibit high strength, high hardness, high toughness, and low thermal conductivity, posing significant challenges to the cutting performance of tools.

(2) Current Application Status of CNC Cutting Tools in the Aerospace Industry

First, the application of high-speed cutting tools.

The aerospace sector has extensively adopted high-speed cutting technology to enhance machining efficiency and surface quality.

High-speed cutting tools, such as cemented carbide-coated tools and ceramic tools, have become mainstream for machining aerospace components.

This is due to their high hardness, exceptional wear resistance, and excellent heat resistance.

Second, the development and application of specialized custom tools.

Researchers and manufacturers have made significant progress in developing and applying specialized custom tools tailored to the complex structures and difficult-to-machine materials of aerospace components.

For instance, using diamond-coated tools to machine carbon fiber composites effectively enhances tool wear resistance and cutting efficiency while minimizing the impact of tool wear on machining quality.

(3) Challenges Faced in the Application of CNC Cutting Tools in the Aerospace Industry

First, short tool life. The difficult-to-machine characteristics of aerospace materials and the complexity of machining processes lead to rapid tool wear and short tool life.

Second, difficulty in optimizing cutting parameters.

For different aerospace materials and machining processes, precise selection of appropriate cutting parameters is required to achieve optimal machining results.

However, the complexity of material properties and the nonlinear nature of the machining process make optimizing cutting parameters challenging.

It often requires extensive experimentation and accumulated experience.

• Automotive Manufacturing Industry

(1) Requirements for CNC Cutting Tools in Automotive Manufacturing

First, high-precision machining demands.

The production of critical components such as electric motors, engines, and transmissions requires extremely stringent dimensional accuracy and geometric tolerances.

This necessitates CNC cutting tools with exceptional precision retention, ensuring stable production of precision parts throughout prolonged, high-volume machining processes.

Second, automotive production demands efficient and durable machining. It is characterized by large-scale, batch manufacturing.

To enhance productivity and reduce costs, CNC cutting tools must enable high-speed cutting and efficient machining.

Simultaneously, tool life is critical—minimizing tool changes effectively improves production line continuity and overall efficiency. Third, adaptability to diverse materials.

Automotive manufacturing involves multiple materials, including aluminum alloys, alloy steels, high-strength steels, and new composite materials.

Significant variations in the physical and chemical properties of these materials impose diverse demands on tool cutting performance.

(2) Current Application of CNC Cutting Tools in the Automotive Manufacturing Industry

First, tool application in turning operations. For machining automotive shaft components, carbide tools and ceramic tools are commonly employed.

Additionally, coated tools see extensive use in turning processes, as coatings significantly enhance tool wear resistance, corrosion resistance, and cutting performance while extending tool life.

Second, tool applications in milling operations.

To achieve high-efficiency, high-precision machining, the automotive industry employs various advanced tooling technologies.

High-speed milling cutters enable stable cutting at elevated rotational speeds, boosting processing efficiency and surface finish quality.

Different milling cutter types—such as ball-nose cutters, end mills, and face mills—are selected and combined appropriately based on specific machining locations and process requirements.

Third, tool application in drilling operations. Drilling in automotive components primarily creates connection holes, oil passages, and similar features.

For deep-hole machining, internal-coolant drills are employed.

These incorporate internal channels that deliver cutting fluid directly to the cutting zone, effectively reducing cutting temperatures and improving chip evacuation.

(3)Challenges Faced in the Application of CNC Cutting Tools in the Automotive Manufacturing Industry

First, the issue of tool intelligence and automation.

With the continuous promotion and application of smart manufacturing technologies in the automotive industry, higher demands are placed on the intelligence and automation levels of CNC cutting tools.

Tools must be capable of performing functions such as automatic identification, automatic tool changes, and tool condition monitoring.

These capabilities enable automated and intelligent control of the machining process.

Second, the issue of tool life. Automotive component machining typically involves high-volume, continuous production over extended periods, placing greater demands on tool life.

The diverse range of materials used in automotive manufacturing—including challenging-to-machine materials like high-strength steel and aluminum alloys—often accelerates tool wear.

This, in turn, shortens tool life.

• Mold Manufacturing Industry

(1) Requirements for CNC Cutting Tools in Mold Manufacturing

First, adaptability to machining diverse mold materials.

Mold manufacturing involves multiple materials, including various mold steels, aluminum alloys, copper alloys, and cemented carbides.

Significant differences in the physical and chemical properties of these materials impose varied demands on cutting tool performance.

Second, the capability to machine complex geometries. Mold structures are intricate, encompassing various free-form surfaces, thin-walled components, and narrow slots.

This necessitates multi-axis (e.g., five-axis) CNC machines paired with compatible tools to achieve precise machining. Tools must also demonstrate excellent adaptability.

Third, high-precision and high-efficiency machining demands.

Mold accuracy is a critical factor determining the final product quality, with dimensional tolerances typically requiring control within ±0.01mm or even stricter ranges.

Additionally, during rough machining stages, tools must rapidly remove large volumes of material to shorten processing cycles and achieve efficient cutting.

(2) Current Application Status of CNC Cutting Tools in the Mold Manufacturing Industry

First, tool applications in milling operations. Ball-nose end mills are widely used in machining complex mold surfaces.

Their spherical cutting edges can contact workpiece surfaces at various angles, enabling precise surface machining.

End mills are commonly used for flat milling, contour milling, and step surface milling in molds.

In mold core machining, end mills can process side walls and bottom surfaces.

Corn milling cutters feature long cutting edges and ample chip clearance, offering significant advantages in mold roughing by rapidly removing large volumes of material.

Second, tool applications in drilling operations.

Twist drills are the most commonly used drilling tools in mold machining, employed for various connection holes, cooling holes, and similar applications.

Deep hole drills are used in mold manufacturing to machine holes with high length-to-diameter ratios, such as cooling water channels.

Deep hole drills ensure the straightness and dimensional accuracy of the drilled holes.

In die casting mold manufacturing, molds must possess superior strength and wear resistance.

This requirement arises from the high temperatures, high pressures, and high-speed impact of molten metal during the casting process.

CNC cutting tools typically employ high-performance materials such as cemented carbide and coated cemented carbide when machining die casting molds.

These tools perform precision machining on critical mold components, such as gates and runners.

This ensures the smooth flow of molten metal within the mold and enhances the quality and yield rate of die casting products.

Furthermore, the single-piece and small-batch production nature of mold manufacturing demands that CNC cutting tools feature rapid tool changes and flexible programming capabilities.

This adaptability addresses the machining requirements of diverse mold structures, shortens mold development cycles, and reduces mold development costs.

(3)Challenges Faced in the Application of CNC Cutting Tools in the Mold Manufacturing Industry

First, tool clamping and dynamic balancing issues.

During high-speed machining, the clamping accuracy and dynamic balancing performance of cutting tools significantly impact machining quality and tool life.

If tools are not securely clamped or poorly balanced, vibrations occur during high-speed rotation, leading to uneven tool wear and surface vibration marks.

Enhancing tool clamping reliability and dynamic balancing precision is crucial for ensuring mold machining quality.

Second, limitations of tool coating technology.

While tool coatings significantly improve cutting performance, existing coatings in mold manufacturing still have certain limitations that can affect tool life.

• Electronic Information Manufacturing Industry

(1) Requirements for CNC Cutting Tools in the Electronic Information Manufacturing Industry

First, ultra-precision machining demands. Chip manufacturing processes are exquisitely detailed, with feature dimensions now entering the nanometer scale.

This necessitates cutting tools possessing ultra-precision cutting capabilities to ensure machining accuracy is controlled within the nanometer range.

Second, high-precision hole machining demands.

PCBs require numerous high-precision vias and mounting holes for electrical connections and component installation.

These holes typically range from 0.1 to 1 mm in diameter, demanding exceptional accuracy in diameter, roundness, and perpendicularity, with tolerances generally controlled within ±0.05 mm.

Third, machining special materials. Chip manufacturing involves diverse specialty materials such as monocrystalline silicon, photoresist, and various metal interconnect materials.

Monocrystalline silicon is highly hard and brittle. During cutting and grinding, tools must exhibit excellent wear resistance and chipping resistance.

Fourth, processing multilayer board structures. PCBs are typically multilayer structures composed of alternating stacked insulating and conductive layers.

During machining, tools must reliably penetrate multiple layers while ensuring smooth transitions between different material layers to prevent issues like delamination or damage.

(2) Current Application Status of CNC Cutting Tools in the Electronics Manufacturing Industry

First, diamond cutting tools and abrasive tools are primarily used in chip manufacturing. Diamond tools are extensively used in silicon wafer cutting and grinding processes.

These tools enable high-precision machining of individual silicon wafers. Abrasive tools are commonly employed in wafer grinding and polishing operations.

During chip manufacturing, grinding and polishing are essential to achieve ultra-smooth wafer surfaces, meeting the requirements for subsequent processes like lithography.

Second, PCB drilling bits and milling cutters are primarily used in printed circuit board (PCB) processing.

PCB drilling bits, the main tools for PCB hole processing, are typically made of cemented carbide. PCB milling cutters are mainly used for PCB contour cutting and slot processing.

Using high-speed milling cutters for PCB contour milling enables high-precision shape processing.

(3) Challenges Faced in the Application of CNC Cutting Tools in the Electronics Manufacturing Industry

First, tool manufacturing precision and consistency. The electronics manufacturing industry demands extremely high precision and consistency in tool production.

Even minor dimensional deviations or variations in cutting edge quality can cause adverse effects during machining, such as uneven chip edges or dimensional deviations in PCB drilling.

Second, tool structure optimization and innovation. Different chip and PCB materials, along with varying machining processes, necessitate precisely matched cutting parameters.

Continuous iteration is required to enhance cutting performance and chip evacuation efficiency while reducing tool wear and machining defects.

• Optical Instrument Manufacturing Industry

(1) Requirements for CNC Cutting Tools in the Optical Instrument Manufacturing Industry

First, complex surface machining capability. Optical components feature intricate shapes encompassing special structures such as aspheric surfaces and freeform surfaces.

These complex surfaces are difficult to manufacture with precision using traditional machining methods and must be processed using CNC machine tools and customized cutting tools.

Second, ultra-high precision machining demands. Optical components within instruments—such as lenses and mirrors—demand near-obsessive precision in surface and geometric accuracy.

Lens curvature radii typically require sub-micron control, while surface roughness must reach the nanometer level.

This ensures precise light refraction and reflection, effectively minimizing aberrations and scattering.

In the machining of high-precision optical lenses, the cutting trajectory of the tool must be accurate to the micrometer level or even smaller.

Third, CNC cutting tools must adapt to special optical materials.

During the manufacturing of optical instruments, manufacturers use various specialized materials, including optical glass, quartz crystal, sapphire, and silicon carbide.

(2)Current Applications of CNC Cutting Tools in the Optical Instrument Manufacturing Industry

First, diamond tools.

Single-crystal diamond tools possess extremely high hardness, outstanding wear resistance, and a low friction coefficient, making them the preferred choice for machining brittle materials such as optical glass and crystal.

During the precision grinding and polishing processes of lenses, single-crystal diamond tools can achieve nanometer-level material removal, producing ultra-smooth surfaces.

Polycrystalline diamond (PCD) tools possess high hardness and wear resistance while overcoming the brittleness drawbacks of single-crystal diamond tools.

They are commonly used for machining high-hardness optical materials like sapphire and silicon carbide. Second, cubic boron nitride (CBN) tools.

These offer high hardness, excellent thermal stability, and strong chemical inertness, making them suitable for machining high-hardness optical materials like ceramics and cemented carbides.

Third, grinding and polishing tools. During the lens grinding and polishing stages, specialized tools like grinding wheels and polishing pads serve as core instruments.

Manufactured with specific materials and processes, they precisely remove minute material surpluses according to lens composition and design requirements.

This reduces surface roughness to the nanometer level, meeting the imaging demands of high-precision optical instruments.

(3) Challenges in Applying CNC Cutting Tools to the Optical Instrument Manufacturing Industry

First, different optical materials and machining processes require precise matching of cutting parameters such as cutting speed, feed rate, and cutting depth.

Second, optical instrument machining demands extremely high precision and stability from machine tools, where the compatibility between tools and machines directly impacts component machining quality.

Factors including tool dynamic performance, tool holder precision, and clamping force must all align with machine tool capabilities.

• Medical Device Manufacturing Industry

(1) Requirements for CNC Cutting Tools in the Medical Device Manufacturing Industry

First, complex structure machining capability. Machining irregular holes and complex cavities:

For instance, fluid channels in surgical instruments or specially shaped holes in dental instruments require precise machining within intricate spaces while maintaining excellent chip evacuation performance.

Thin-walled structure machining:

Tools must exhibit high rigidity and low cutting forces to prevent thin-wall deformation, ensuring machining accuracy and product quality.

Second, High Precision and Surface Quality Demands. Medical devices impose extremely stringent dimensional accuracy requirements.

For instance, the fit tolerance between joint ball heads and acetabular cups is typically controlled within ±0.01mm.

Surface quality demands are even higher, with surface roughness values (Ra) required to reach 0.2–0.4 μm.

This necessitates tools capable of ultra-precision cutting to produce smooth surfaces.

Third, suitability for machining diverse medical materials. Common metals in medical device manufacturing include stainless steel, titanium alloys, and cobalt-chromium alloys.

These materials feature high strength and corrosion resistance. Additionally, tools must accommodate polymer materials, which exhibit distinct machining characteristics.

Appropriate tool geometry and cutting parameters are essential to prevent thermal deformation and tearing of these materials. Fourth, micro-dimension requirements.

To enable device operation within confined spaces, specialized micro-sized tools such as micro-drills and micro-milling cutters are often required.

(2)Current Applications of CNC Cutting Tools in the Medical Device Manufacturing Industry

First, tool applications in milling operations. Ball-nose end mills are widely used for machining complex curved surfaces in medical devices.

End mills are commonly employed for processing flat surfaces, contours, and grooves in medical device structures.

Additionally, end mills can be utilized for machining thin-walled structures in medical devices.

By appropriately selecting tool diameter and number of cutting edges, cutting forces can be controlled to minimize thin-wall deformation.

Second, tool applications in drilling operations. Twist drills are commonly used for holemaking in medical device manufacturing.

When machining holes with high length-to-diameter ratios—such as intramedullary nail holes in orthopedic implants—deep hole drills ensure drilling straightness and dimensional accuracy.

Third, tool applications in turning operations. External turning tools are commonly used for machining shaft components in medical devices.

Internal turning tools are employed for processing internal bore structures.

By precisely controlling cutting parameters during machining, these tools ensure the cylindricity and surface roughness of internal bores.

(3)Challenges Faced in the Application of CNC Tools in the Medical Device Manufacturing Industry

First is the balance between machining precision and efficiency. In medical device manufacturing, ensuring machining accuracy while improving production efficiency is essential.

However, achieving both simultaneously proves challenging in actual production.

Increasing cutting speed may boost efficiency but can accelerate tool wear, compromising machining accuracy.

Second is the compatibility between tools and machine tools.

Medical device processing demands higher precision and stability from machine tools, with Swiss-type machine tools being the primary choice within the industry.

• Watch Manufacturing Industry

(1) Requirements for CNC Cutting Tools in Watch Manufacturing

First, demand for ultra-micro precision machining.

Extremely small dimensional accuracy requirements:

Mechanical watch components are minuscule in size, such as the balance spring and escape wheel within the movement, often requiring dimensional accuracy controlled at the micrometer level.

The diameter tolerance of a balance spring must be precisely controlled to ±0.001mm.

This demands CNC cutting tools with exceptional micro-cutting precision, capable of performing accurate machining within extremely confined spaces to ensure component dimensional accuracy.

Additionally, ultra-high surface quality is required: the surface finish of mechanical watch components directly impacts the watch’s performance and aesthetics.

The dial surface must achieve a mirror-like finish with a surface roughness Ra value of 0.05–0.1 μm, necessitating tools capable of ultra-precision surface machining.

Second, the capability to process complex, intricate structures.

Complex gear and cam machining:

Mechanical watch movements contain numerous intricate gear and cam structures.

The precision of these components’ tooth profiles and contours is critical to the movement’s transmission performance.

Micro-hole and slot machining:

Mechanical watch components also feature numerous minute holes and slots for part connection, positioning, and functional implementation.

The machining precision of these micro-features demands exceptionally high standards.

Cutting tools must not only possess high-precision positioning capabilities but also exhibit excellent chip evacuation performance to prevent chips from compromising machining quality.

(2) Current Applications of CNC Cutting Tools in the Watch Manufacturing Industry

First, tool applications in milling operations.

Micro ball-end mills are commonly used to machine complex curved components in watches, such as three-dimensional decorative patterns on dials and curved contours of watch cases.

Micro end mills are frequently employed for machining flat surfaces, contours, and slots in watch components.

During movement part processing, these tools precisely mill various shaped slots and holes to meet functional requirements. Second, tool applications in drilling operations.

Micro twist drills are commonly used drilling tools in watchmaking.

When machining connecting holes and mounting holes in various watch components, micro twist drills leverage their miniature size and high precision to drill accurate small holes.

When machining extremely small-diameter micro-holes—such as those on hairspring fixing pins requiring diameters as small as 0.05mm or less—micro-hole drills excel.

Third, tool applications in turning operations. Micro external turning tools play a critical role in machining shaft components for watchmaking.

Hand shaft diameters typically range from 0.1 to 0.3mm, demanding extremely high surface roughness and cylindricity.

Micro internal turning tools are used for machining internal bore structures in watch components, such as the inner bore of a watch crown.

For a particular Swiss watch brand’s crown machining, the inner bore diameter is specified at 1.5mm with a tolerance of ±0.003mm, and the surface roughness value Ra must reach 0.1μm.

(3) Challenges Faced in the Application of CNC Cutting Tools in the Watch Manufacturing Industry

First, challenges posed by material diversity and minute dimensions.

Different watchmaking materials and minuscule component sizes demand precise matching of cutting parameters.

However, due to the complexity of material properties and the unique machining characteristics at such small scales, current parameter selection often relies on experience and extensive trial runs.

Swiss-type machine tools currently dominate the industry. Second, wear resulting from micro-scale machining.

Watch components are minuscule, subjecting cutting edges to complex forces during machining.

Heat generated during cutting dissipates poorly, accelerating tool wear.

• Pen and Stationery Manufacturing Industry

(1) Requirements for CNC Cutting Tools in the Pen and Stationery Industry

First, high precision and consistency demands. Writing components require high precision.

For pen products, the accuracy of writing parts like nibs and ballpoint tips directly impacts writing smoothness and ink flow control.

The diameter tolerance for ballpoint pen tips typically needs to be controlled within ±0.002mm.

Pen and stationery production involves large-scale batch manufacturing, demanding consistent quality and dimensions across every product.

Tools must ensure identical machining precision for each workpiece.

Second, precision machining of internal structures. Some stationery products feature intricate internal mechanisms, such as spring clips or refill-advancing mechanisms.

These internal structures require high machining accuracy, demanding tools capable of fine cutting within confined spaces. Third, suitability for diverse materials.

Plastic processing: Plastic is one of the most common materials in pen and stationery manufacturing, offering advantages like ease of machining and low cost.

However, it is prone to deformation and burr formation during processing.

Cutting tools must possess appropriate geometries and cutting parameters to minimize thermal deformation of plastics.

Metal Material Machining: For premium pens and metal stationery items like fountain pen nibs and metal clips, materials such as stainless steel and copper alloys are employed.

These metals exhibit high hardness, demanding superior tool wear resistance and cutting performance.

Carbon Fiber Material Machining: Carbon fiber materials possess directional fiber properties and a tendency to delaminate.

Tools must be capable of adapting to these machining characteristics.

(2) Current Applications of CNC Cutting Tools in the Pen and Stationery Manufacturing Industry

First, tool applications in milling operations. Micro ball-end mills are used to machine complex curved surfaces and decorative patterns on pen barrels.

End mills are commonly employed for flat milling, slot machining, and processing internal structures of stationery items, ensuring assembly precision of components. Second, tool applications in drilling operations.

Twist drills are commonly used drilling tools in pen and stationery manufacturing.

They are employed to machine ink feed holes, connection holes, and other openings in pen barrels.

Micro-drills are used to machine ink flow channels in fountain pen nibs, where the diameter of these channels typically ranges from 0.1 to 0.3 mm.

Through specialized design and manufacturing processes, micro-drills achieve high-precision drilling at these minute dimensions.

(3) Challenges Faced by CNC Cutting Tools in the Pen and Stationery Industry

First, in the machining of ballpoint pen tips, CNC cutting tools must precisely fabricate intricate structures like ball seats and ball bearings within extremely confined spaces.

This ensures smooth ball rotation during writing and uniform ink flow. Additionally, the industry’s automation demands place specific requirements on cutting tools.

As automation levels increase, tools must feature rapid changeover capabilities, automatic tool recognition, and excellent compatibility.

Only then can they adapt to automated production lines, enabling swift and accurate tool changes to ensure continuous and stable production processes.

Advancements in CNC Tooling Technology

• Tool Materials

(1) Novel Cemented Carbide Materials

Through optimizing the composition and preparation processes of cemented carbide, new materials with enhanced hardness, toughness, and wear resistance have been developed.

These enable tools to withstand higher cutting forces and temperatures, thereby improving cutting efficiency and tool life.

For instance, cemented carbide tools incorporating rare metal elements demonstrate outstanding performance when machining high-strength alloy steels and heat-resistant alloys.

(2) Expanding Applications of Superhard Materials

The application scope of superhard materials such as diamond and cubic boron nitride continues to broaden.

Cubic boron nitride cutting tools achieve high-precision, high-efficiency machining with extended tool life when performing high-speed cutting of hardened steel, cast iron, and similar materials.

Concurrently, nanostructured superhard materials are under development and application, promising further enhancements in tool performance.

(3) Innovative Applications of Coating Technologies

These primarily include the following categories:

1)  Multicomponent Composite Coatings:

Multicomponent composite coatings prepared using technologies such as Physical Vapor Deposition (PVD) and Chemical Vapor Deposition (CVD), including titanium aluminum nitride (TiAlN), chromium aluminum nitride (CrAlN), titanium silicon nitride (TiSiN), and chromium nitride (CrN).

These coatings combine the advantages of multiple materials, offering enhanced hardness, wear resistance, oxidation resistance, lubricity, and corrosion resistance.

They significantly improve tool performance under high-speed and dry cutting conditions.

2)  Nanocoatings:

Advancements in nanocoating technology have produced denser and more uniform coating microstructures.

These coatings have thicknesses precisely controlled at the nanoscale, which further enhances cutting performance and extends tool life.

For instance, nanodiamond-coated tools demonstrate excellent cutting results when machining non-ferrous metals and composite materials.

3)  Adaptive Coatings:

Certain novel coatings can automatically adjust their properties based on conditions such as temperature and pressure during the cutting process.

For instance, they form more stable oxide films at high temperatures, providing thermal insulation and lubrication to effectively reduce tool wear and cutting forces.

• Tool Design and Manufacturing

(1) Breakthrough in Virtual Tool Design Technology

In 2024, ANCA partnered with Tetralytix to achieve seamless integration from modeling to simulation for CNC tools.

This accelerated the entire process from design to validation, shortened development cycles, and reduced costs.

Tool designers can now precisely predict tool performance through simulation analysis before the first trial cut.

This represents “digital twin” technology in the tool industry’s design phase.

(2) Tool Optimization Structural Design

First is the optimization of complex tools.

To meet the machining demands for complex-shaped components in aerospace, automotive, and other industries, the structural design of complex tools is continuously refined.

Simultaneously, lightweight and high-efficiency designs are achieved.

To adapt to high-speed cutting and automated machining requirements, lightweight tool design has become a prevailing trend.

Furthermore, chip evacuation performance has been significantly enhanced.

Tool structures are now engineered to facilitate smoother chip removal, preventing clogging and improving machining quality.

(3) Applications of 3D Printing Technology

3D printing technology is now being applied in the field of CNC tool manufacturing, enabling rapid prototyping and customized production of complex cutting tools.

Through 3D printing, tool structures featuring internal cooling channels and specialized geometries—which are difficult to achieve with traditional manufacturing methods—can be produced.

This provides new avenues for enhancing tool performance and enabling innovative designs.

(4) High-Precision Ultra-Small-Diameter Tool Manufacturing Technology

A certain brand of high-precision CNC tool grinders can now mass-produce ultra-small-diameter tools as small as 0.03mm.

Integrated tool measurement and progressive automation capabilities deliver exceptional efficiency for manufacturers of ultra-small-diameter tools.

• Tool Cutting Processes

(1) Advancements in High-Speed Cutting Technology

With continuous progress in machine tool and cutting tool technologies, high-speed cutting techniques have seen extensive application.

For instance, in the aerospace sector, manufacturers employ high-speed cutting to process difficult-to-machine materials, such as aluminum alloys and titanium alloys.

This approach significantly enhances both machining efficiency and part quality.

(2) Maturity of Hard Cutting Technology

As a key application area of high-speed cutting technology, hard cutting has reached maturity.

Utilizing super-hard tools, manufacturers machine high-hardness materials such as hardened steel and chilled cast iron.

This approach not only replaces traditional grinding processes, enhancing machining efficiency and flexibility, but also achieves superior machining accuracy and surface quality.

Hard cutting technology has found extensive application in industries such as automotive and mold manufacturing, exemplified by the use of CBN tools for machining hardened gears and mold cavities.

(3) Promotion of Dry Cutting and Minimal Lubrication Cutting

Currently, dry cutting and minimal lubrication cutting technologies have garnered significant attention and promotion.

By optimizing tool coatings and cutting edge designs, along with employing appropriate cutting parameters, efficient machining can be achieved with little or no cutting fluid usage.

This approach not only reduces processing costs but also aligns with the development trend of green manufacturing.

• Intelligent, Digital, and Integrated Aspects

(1)  Research, Development, and Application of Intelligent Cutting Tools

Intelligent cutting tools incorporate advanced sensors to enable online monitoring and adaptive control technology.

These sensors continuously track parameters such as cutting force, cutting temperature, and tool wear during machining, analyzing and processing this data through intelligent algorithms.

Based on monitoring results, they automatically adjust cutting parameters like spindle speed and feed rate to achieve adaptive control of the cutting process.

This ensures tools remain in optimal working condition, enhancing machining accuracy and tool life.

(2) Tool Integration in Smart Manufacturing Systems

Within digital workshop environments, the Tool Management System (TMS) closely collaborates with Enterprise Resource Planning (ERP) and Manufacturing Execution Systems (MES) to establish a comprehensive data loop across the entire process.

An intelligent tool management system comprehensively manages and optimizes tool procurement, inventory, usage, and maintenance.

Through data analysis and predictive insights, the system enables rational tool allocation and timely supply.

This reduces tool inventory and management costs while enhancing production efficiency and equipment utilization.

(3)  Innovative Practices in Composite Tools

Composite tools have become exemplary solutions for enhancing machining efficiency and precision.

Turning-milling composite tools, as a prime example, integrate turning and milling functions to achieve multi-process coordination in a single setup.

Drilling-reaming composite tools are widely used in precision mold manufacturing.

They combine drilling and reaming capabilities, significantly improving the accuracy and quality stability of hole system machining.

Future CNC cutting tools are expected to integrate more functions, enabling comprehensive optimization of the machining process.

Challenges and Countermeasures in CNC Tool Machining

• Challenges in Machining

(1)  Technical Challenges in High-Precision Machining

Key industries now demand increasingly stringent precision requirements for components, entering the realm of sub-micron and even nanometer-level accuracy.

In this high-precision machining domain, CNC tools face numerous issues and challenges.

First is tool wear control. As machining precision increases, even minor wear during cutting can cause dimensional deviations and surface quality deterioration in workpieces.

During high-precision cutting, the contact area between the tool and workpiece is extremely small.

This concentrates cutting forces and causes localized stress spikes at the cutting edge, which accelerates tool wear.

Simultaneously, the generation and accumulation of cutting heat significantly impact tool wear, as elevated temperatures reduce the hardness and strength of tool materials.

Secondly, optimizing cutting forces is equally crucial.

In high-precision machining, unstable cutting forces readily cause workpiece deformation and vibration, thereby compromising machining accuracy.

For precision components like thin-walled parts and micro-structural components, even minor fluctuations in cutting forces can cause significant damage.

Cutting forces are influenced by multiple interacting factors, including tool geometry, cutting parameters, and workpiece material properties.

This makes accurate modeling and optimization extremely challenging.

Traditional, experience-based cutting force control methods can no longer meet the demands of high-precision machining.

(2)  Challenges in Machining Difficult-to-Cut Materials

In sectors such as aerospace and power generation, components made from difficult-to-machine materials like titanium alloys and high-temperature alloys are prevalent.

The machining characteristics of these materials pose significant challenges for CNC cutting tools.

First is the issue of insufficient tool heat resistance.

Take titanium alloy machining as an example. Its low thermal conductivity makes it difficult to dissipate the substantial heat generated during cutting quickly.

As a result, localized temperatures on the cutting edge rise sharply.

In high-temperature environments, traditional tool materials like cemented carbide experience significant reductions in hardness and strength, leading to rapid tool wear and even chipping.

Another issue is the insufficient toughness of the tool material.

Due to their complex alloy composition and microstructure, high-temperature alloys exhibit a strong tendency toward work hardening during cutting, generating immense and highly fluctuating cutting forces.

This demands tools with exceptional toughness to withstand high-frequency impact loads and prevent brittle fracture.

• Strategic Responses

(1)  Increase R&D Investment and Strengthen Industry-Academia-Research Collaboration

Faced with intense competition in the CNC tooling market and the challenge of rapid technological iteration, increasing R&D investment and enhancing industry-academia-research collaboration have become the path to breaking through development bottlenecks and advancing toward high-end manufacturing.

(2) Optimizing Industrial Ecosystems and Brand Development

Optimizing industrial ecosystems and strengthening brand development are crucial measures for enhancing the overall competitiveness of the CNC cutting tool industry and achieving sustainable development.

In building industrial ecosystems, efforts should focus on creating a coordinated industrial chain that integrates upstream and downstream operations.

Brand development is equally important. First, enterprises must leverage their deep technical expertise to produce high-performance, high-precision cutting tools.

Second, by strictly adhering to international standards and establishing modern production management systems, they should gradually build a premium tool brand image.

This approach will break the monopoly of other brands in the high-end market, enhance the brand’s international influence, and strengthen its market competitiveness.

Concurrently, industry associations should serve as bridges and connectors, organizing enterprises to engage in technical exchanges, standard-setting, and market promotion activities.

This collaborative approach will collectively elevate the visibility and competitiveness of regional industrial clusters, propelling the CNC tool industry toward high-quality, brand-driven development.

Concluding Remarks

CNC tool manufacturers are advised to initiate efforts in the following areas:

First, explore how to leverage big data analytics to uncover latent value within tool usage data, enabling tool life prediction and machining quality optimization.

Second, utilize artificial intelligence technology to achieve intelligent tool design and machining decision-making.

Third, build an intelligent tool management system based on the Internet of Things to enhance production efficiency and resource allocation effectiveness.

Fourth, explore innovative applications of additive manufacturing in tool repair and customized production.

Looking ahead, CNC cutting tools will deeply integrate into the smart manufacturing ecosystem, opening broader market prospects in expanding new application domains.

Additionally, CNC tool processing techniques will integrate emerging technologies such as big data, artificial intelligence, IoT, and additive manufacturing.

Through technological innovation and industrial transformation, continuous breakthroughs will forge new productive forces, creating sharper “tools” for the high-quality development of global manufacturing.

Together, these advancements will propel the manufacturing sector toward higher levels of intelligent upgrading.