Advanced materials science improves the performance and lifespan of tools

By Staff Report December 30, 2024 5:30 pm IST

TaeguTec uses advanced materials like PVD-coated tungsten carbide, ceramic, and cermet grades to enhance tool performance and lifespan. L. Krishnan, Managing Director of TaeguTec India Private Limited, explains how these materials are used across various industries and how they cater to the needs of each sector.

What new materials have TaeguTec introduced to improve cutting tool performance and extend lifespan?

We leverage advancements in material science to improve the performance and lifespan of our tools, ensuring our customers achieve optimal productivity and cost-efficiency. Tungsten Carbide with advanced coatings is one of them. Tungsten carbide, known for its hardness and wear resistance, forms the base material for many of our cutting tools. We enhance its properties through the application of advanced coatings, such as titanium nitride (TiN), titanium carbonitride (TiCN), and titanium aluminium nitride (TiAlN). These coatings increase wear resistance, reduce friction, and improve heat dissipation, contributing to longer tool life and improved cutting performance. For example, our TT9080 grade , with its advanced PVD coating, is specifically designed for high-speed steel machining, offering excellent wear resistance and toughness.   

Cermet and ceramic grades exhibit superior hardness and wear resistance at high temperatures, making them ideal for high-speed machining applications. Our cermet and ceramic inserts withstand extreme cutting conditions, delivering exceptional performance and extended tool life in demanding applications. For instance, our TT6080 cermet grade excels in high-speed finishing of cast iron components, common in the Indian automotive industry.

What advanced tool geometries do you use to reduce machining time?

We design our cutting tools with precision geometries that enhance chip evacuation, minimise cutting forces, and improve surface finish.  We have chip breaker technology where our inserts incorporate specifically engineered chip breakers to break chips into small, manageable sizes. This prevents chip clogging and ensures efficient chip evacuation. We can reduce our cutting forces, improve surface finish, and increase the life of our tool. This is especially crucial in the Indian context, where varied machining conditions and materials are prevalent.

Our tool geometries employ optimised rake and clearance angles to minimise cutting forces and reduce heat generation. This leads to faster cutting speeds, improved surface quality, and extended tool life. For example, our WinSFeed line of high-feed milling cutters features optimised geometries for high metal removal rates and smooth cutting action.  

What cooling techniques do you use to improve tool life and reduce wear?

Effective cooling is essential for maintaining tool life and reducing wear, especially in high-speed machining operations. We have a range of cooling solutions to address the specific needs of our customers. Our cutting tools are designed with internal coolant channels that deliver coolant directly to the cutting edge. This ensures efficient heat dissipation, reduces tool wear, and improves chip evacuation, resulting in longer tool life and enhanced cutting performance. This is particularly important in India, where high ambient temperatures affect tool life.  

Our high-pressure systems deliver coolant at significantly higher pressures, enhancing penetration and heat dissipation at the cutting zone. This is beneficial in challenging applications, such as deep-hole drilling and high-speed milling, where conventional cooling methods may be insufficient. This technology is increasingly being adopted in the Indian aerospace and defence sectors, where maintaining high precision and tight tolerances is essential.  

What advantages do you get from superhard materials like CBN and PCD?

Superhard materials, such as cubic boron nitride (CBN) and polycrystalline diamond (PCD), offer significant advantages over traditional cutting tools in terms of wear resistance. We use these materials to provide cutting solutions for demanding applications.

CBN exhibits exceptional wear resistance, especially at high temperatures, making it ideal for machining hardened steels, cast iron, and superalloys. Our CBN inserts deliver superior performance and extended tool life in these challenging applications. The demand for these materials is growing in the Indian automotive industry, particularly for machining hardened components such as gears and shafts.

PCD offers unmatched wear resistance and is particularly effective in machining non-ferrous materials, such as aluminium, copper, and composites. Our PCD tools extend tool life and provide a superior surface finish in these applications. With the growth of many industries in India, the demand for high-precision PCD tooling for machining components is increasing.   

How does TaeguTec integrate AI, ML, and IoT in cutting tool management?

We are actively exploring these technologies for tool utilisation, predicting tool wear, and improving overall process efficiency.  AI and ML algorithms can analyse vast amounts of data collected from sensors embedded in cutting and machine tools. This data includes cutting parameters, vibration levels, and temperature readings. With the help of this data, AI and ML can predict tool wear, optimise cutting parameters, and schedule tool replacements proactively, minimising downtime and maximising efficiency.  

IoT connectivity enables real-time monitoring of cutting and machine tools, providing valuable insights into tool performance and process efficiency. As Industry 4.0 adoption accelerates in India, these technologies will play a key role in boosting the nation’s competitiveness.

What role do you see IMTEX 2025 playing in fostering global collaborations and advancing industry partnerships?

We actively participate in IMTEX to showcase our latest innovations and engage with customers and partners. IMTEX provides an opportunity to connect with industry leaders, explore emerging technologies, and forge new partnerships. It facilitates knowledge sharing, technology transfer, and collaboration among cutting tool builders, machine tool manufacturers, and end-users.   

IMTEX 2025 is an ideal platform to showcase our WinSFeed line of high-feed milling cutters. These cutters are designed to deliver exceptional metal removal rates, reduce machining time, and improve surface finish. With their unique geometries and advanced coatings, WinSFeed cutters are well-suited for applications in the Indian manufacturing landscape, including the automotive, aerospace, and die & mould industries.