Tech, ExplainedIndustrial tech and mobility
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Cutting tools

The tips that wear out doing the cutting.

INSIDE: CNC MACHINESHOW IT WORKS · 100 STEEL BRACKETS CUT WITH CARBIDE INSERTSThe batchneeds 100brackets, eachwith 6 minutesof cutting:600 minutesOne cuttingedge lastsabout 25 minutesin this steelSo the batchneeds 600 ÷ 25 =24 cutting edgesEach insert has4 edges, so 24 ÷4 = 6 insertsAt ₹450 each,the insertscost ₹2,700for the batchWhen an edge isworn, theoperator turnsthe insert to anew edgeINSIDE: CNC MACHINESHOW IT WORKS · 100 STEELBRACKETS CUT WITH CARBIDE INSERTSThe batch needs100 brackets, eachwith 6 minutes ofcutting: 600 minutesOne cutting edgelasts about 25minutes in this steelSo the batch needs 600 ÷25 = 24 cutting edgesEach insert has 4 edges,so 24 ÷ 4 = 6 insertsAt ₹450 each, the insertscost ₹2,700 for the batchWhen an edge is worn, theoperator turns the insertto a new edgeINSIDE: CNC MACHINES · 100 STEEL BRACKETS CUTWITH CARBIDE INSERTSThe batch needs 100 brackets, each with 6minutes of cutting: 600 minutes↓One cutting edge lasts about 25 minutesin this steel↓So the batch needs 600÷ 25 = 24 cutting edges↓Each insert has 4 edges,so 24 ÷ 4 = 6 inserts↓At ₹450 each, the inserts cost ₹2,700 forthe batch↓When an edge is worn, the operator turnsthe insert to a new edge
A cutting tool is pressed against the metal by the CNC machine, wears down with each part, and is then turned to a fresh edge or replaced.
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Cutting tools are the hard tips and inserts that do the actual cutting inside a machine tool. A CNC machine only moves them. The tip touches the metal, so it wears out, and it has to be replaced again and again.

An insert is a small piece of a very hard material, usually tungsten carbide, shaped like a square or a triangle. It is screwed onto a holder. It has several cutting edges. When one edge is worn, the operator turns the insert to a fresh edge. When all edges are worn, the insert is thrown away and a new one is fitted. Inserts are often coated with a thin layer of a harder material, which lets them cut faster before they wear. Different metals need different inserts: aluminium cuts easily, while stainless steel is hard on the tip.

Consider what happens when a programmer raises the cutting speed. At the normal speed, a bracket takes 6 minutes to cut and an edge lasts 25 minutes. At the higher speed, a bracket takes 5 minutes, but an edge lasts only 15 minutes. For 100 brackets, the faster speed saves 100 minutes of machine time, which is worth ₹1,500 at ₹900 an hour. But it needs 34 edges, or 9 inserts costing ₹4,050, in place of 6 inserts costing ₹2,700. So the faster speed gains only about ₹150. The CAM software and the programmer must weigh both costs, because cutting faster makes an edge wear out sooner.

Worn tips also spoil the part. A blunt edge makes the sizes drift, and the part may leave its tolerance. A blunt edge also leaves a rough surface and can make the machine shake. So workshops change tips on a schedule, or when the machine measures a rising force on the tool.

For a tool maker, this is a business that repeats, because every machine keeps buying new tips for as long as it runs. It is a clear case of aftermarket sales. Some tool makers also make the software that programs their tools.

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