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When first introduced in the late 1970s, cutting tool coatings—especially titanium nitride (TiN)—were embraced by tool manufacturers for their ability to extend tool life. As workforce materials have expanded from conventional ferrous and nonferrous metals to exotic alloys, composites, ceramics, and others, coatings have likewise progressed and, thanks to new formulations and deposition methods, are extending cutting tool capabilities as well as tool life.

Digital tool management systems, and the digital tool libraries that support them, are changing the way cutting tools, toolholders and workholding are assembled into tooling setups and used to machine parts

Manufacturing Engineering asked thought leaders at five companies for their views on challenges and trends facing the metalworking industry.

Advanced tool grinding technology, more capable and precise than ever, has meant new ground-breaking cutting tools, such as a variable geometry designs. Just as importantly, other machine tool providers need to offer automation and advanced in-process sensing to make proven tool grinding operations even more efficient.

Secure, accurate workholding sets the stage for consistent machining productivity. Depending on the parts and processes involved, workholding can be as simple and temporary as a plain vise or clamp or as complex and permanent as a machined and fabricated fixture that is custom-designed to hold a unique part.

At Jaktool LLC (Cranbury, NJ), a team of young inquisitive engineers is investing the time to explore the full potential of its manufacturing software and machines to take on the complex jobs no one else wants. Using Mastercam CAD/CAM programming software from CNC Software Inc. (Tolland, CT), Jaktool is able to save setup times and tooling costs, and reduce cycle times, while delivering exceptional customer service to a diverse cross section of industries.

With the latest product lifecycle management (PLM) tools, manufacturers take aim at speeding developments using the Digital Thread, an integrated set of CAD/CAM/CAE and cPDM (collaborative Product Data Management) solutions that weave together new Digital Twins of manufacturing processes.

Launched in November 2016 at FABTECH, Squeaks is a mobile-first Industrial Internet of Things [IIoT] messaging app that facilitates quicker, better decision-making and closed-loop collaboration, with machines as part of the conversation.

Tool life, geometry, and stability largely depend on proper edge preparation. Tool Flo, located in Houston, TX, is a manufacturer of carbide cutting tools such as inserts for threading, turning, and milling. The company uses optical 3D measurement systems from Alicona Corp. (Bartlett, IL) in the quality assurance of inserts.

A team of researchers at the Georgia Institute of Technology (Atlanta) have developed a new type of ransomware that was able to take over control of a simulated water treatment plant in a recently conducted test.