Potentials of Additive Manufacturing for Cutting Tools: A Review of Scientific and Industrial Applications
Abstract
:1. Introduction
2. Fundamentals of Additive Manufacturing
2.1. AM Process Variants
2.2. AM Market Relevance
2.3. Processable Materials Relevant to the Application in Cutting Tools
2.3.1. Materials for Tool Carriers
2.3.2. Materials for Tool Substrates
Material | AM Process | Alloy | Properties | Ref. |
---|---|---|---|---|
HSS | Conventional PM steel | ASP2030 (HS6-5-3-8, 1.3244) | H = 990 HV (heat-treated) | [105] |
PBF-LB | M50 (80MoCrV42-16, 1.3551) | H = 789 HV (as-built); H = 803 HV (heat-treated) | [107,109] | |
M2 (HS-6-5-2C, 1.3343) | H = 640 HV; Rm = 1300 MPa (as-built) | [106,108] | ||
ASP2030 (HS6-5-3-8, 1.3244) | H = 654–817 HV (as-built); H = 991 HV (heat-treated) | [110,113] | ||
DED | HS11-2-5-8 (S390PM) | H = 791–825 HV (as-built) | [114] | |
WC-Co | Conventional sintered | WC-10%Co | H = 1450–1590 HV (heat-treated) | [115] |
PBF-LB | WC-18%Co | H = 820–840 HV (as-built) | [116] | |
WC-17%Co | H = 584–663 HV (as-built); H = 900–1050 HV (heat-treated) | [112] [102] | ||
WC-12%Co | H = 863 HV (as-built); H = 1086–1106 HV (heat-treated) | [117] | ||
PBF-EB | WC-13%Co | H = 915–970 HV (as-built) | [118] | |
BJT | WC-12%Co | H = 1050–1306 HV (heat-treated) | [119,120,121,122] | |
WC-10%Co | H = 1119 HV (heat-treated) | [119] | ||
Slurry-based three-dimensional printing (3DP) | WC-10%Co | No information | [123] | |
Ceramics | Conventional sintered | ZTA | H = 1799 HV (heat-treated) | [124] |
VPP | ZTA | H = 1833 HV; σ = 779 MPa (heat-treated) | [124] | |
SiAlON | No information | [104] |
3. Potentials of Additive Manufacturing for Improved Tool Functionalities
3.1. Potentials for Improved Cooling and Cutting Fluid Supply
Tool Type | Workpiece Material | Ref. | Main Findings |
---|---|---|---|
Turning tool holder | CGI-450 | [158,159,160] | Integration of dual nozzle geometries for CO2-snow supply, design of a Ranque–Hilsch vortex tube for cold air generation, higher cooling rate |
CGI-250 | [161] | Improved wetting of cutting edge due to large amount of small outlet nozzles (diameter d = 0.25 mm); comparable cutting forces to conventional tool | |
Ti-6Al-4V | [162] | Combination of MQL and LN2 cooling in PBF-LB-manufactured grooving tool, increase in tool life and productivity due to improved and combined cooling of rake face and major and minor flank face | |
Ti-6Al-4V | [163] | Internally cooled turning tool holder with copper heat sink; combination of external cutting fluid supply and internal cooling reduced overall ecological impact | |
- | [164,165,166,167] | Grooving tool with combined cooling of rake face and major and minor flank face | |
Indexable milling tool | 42CrMo4 + QT | [168] | Single-row milling tool with rake face cooling as a combination of L-shaped and round nozzles; tool life increase of 67% |
Ti-6Al-4V | [169] | Single-row milling tool with combined cooling of rake and minor flank face with three round nozzles (diameter d = 1.5 mm); no tool life increase | |
Ti-6Al-4V | [170] | Life cycle assessment of single-row milling tool with rake face cooling as a combination of L-shaped and round nozzles; tool life increase of 45% | |
Ti-6Al-4V | [171] | Helical milling tool with individualized nozzle design (combination of L-shaped and elliptical nozzles directed on rake face); tool life increase of 27%, chip volume reduction of 25% | |
- | [172,173] | Side-milling cutter with increased tool life due to improved cooling and lubrication (two nozzles directed towards rake face) | |
Ti-6Al-4V | [174] | Single-row milling tool with cooling of major flank face with five round nozzles; 60% increase in tool life | |
- | [175] | Tool carrier (material: 1.4404) for PCD inserts with adapted circular channel design; no machining tests | |
Drilling tool | bone | [176,177] | Internally cooled bone drill (material: 1.4404) with conformal cooling, reduction of temperature in the cutting zone |
- | [178,179,180,181] | Indexable drill with triangular supply channels; reduced pressure losses and increase in conveyed volume flow | |
Threading tool | 42CrMo4 + QT | [105,182] | Thread cutting and forming tools from ASP2030 with adapted nozzle design (elliptical and triangular nozzles)—no significant improvement remained for tool life |
Form turning tool | Ti-6Al-4V | [183] | Form turning tool of WC-17%Co with internal cutting fluid supply on rake and flank face (round and elliptical nozzles) without any subsequent post-processing; no catastrophic failure in turning test |
3.2. Potentials for Improved Damping and Vibrational Behaviors
3.3. Potentials for Lightweight Design and Topology Optimization
3.4. Potentials for Functional Integration
4. Derived Research Needs for AM Cutting Tools
- Design of the internal cutting fluid supply: The geometrical design of AM cutting tools, particularly regarding the internal cutting fluid supply, often lacks a systematic methodology. CFD simulations can optimize the design for desired fluid flow [240,241]. However, achieving an optimal cutting fluid supply requires a deeper understanding of the relationships between heat generation and dissipation during machining, the cooling and lubrication effect of the supplied cutting fluid, and the resulting tool wear phenomena. Currently, there are no systematic design guidelines for optimizing a cutting fluid supply based on the cutting process, workpiece material, and process parameters while also considering the design possibilities of AM.
- Geometrical tool features: AM techniques such as PBF-LB and BJT allow for the processing of hard materials, such as cemented carbide, applicable for the cutting wedge. Research has primarily focused on developing the AM process rather than on exploring the additional potentials of AM regarding the integration of geometrical structures. These potentials can be harnessed for the individualized, process-specific designs of favorable tool micro-geometry, such as flank face modifications, complex chip-breaking geometries, and textured or porous structures that improve frictional conditions. Integrated channels for enhanced cooling or chip-breaking geometries that do not require subsequent post-processing are also possible. Compared to conventional pressing and sintering, AM offers highly flexible geometrical variations that allow for rapid development and designs tailored to specific machining conditions.
- AM for repair of cutting tools: The feasibility of tool repair has been demonstrated in DED processing of HSS for broaching tools [114]. However, the machining performance of such repaired tools remains unexplored. From a sustainability perspective, AM holds great potential for material savings and extending tool life. Thus far, the entire process chain for AM cutting tool repair has not been fully explored. Future developments could include continuous and automatic acquisitions of local tool wear on each cutting edge, preparation for repair (for example, grinding, blasting, or chemical ablation), AM repair, and post-processing of the cutting edge via grinding and coating.
- Functional integration of sensors and actuators: The manufacturing of complex geometries and new AM process variants allows the integration of electronics such as sensors and actuators [236]. This enables real-time monitoring and control of the cutting process. Compared to existing systems, AM offers advantages regarding the compactness of the integrated electronics, proximity of sensors and actuators to the region of interest, and ease of mounting. Further developments in self-sufficient energy supplies, such as energy harvesting and the printing of electronic components, could lead to a deeper understanding of the cutting process and enable online process control.
- Processable alloys for tool substrate and tool carriers: AM facilitates the processing of new alloys, enabling rapid alloy development. On the one hand, low-cost steel alloys with sufficient mechanical properties can reduce tool costs, especially for tool carriers. The PBF-LB manufacturing of tool carriers should allow their use in the as-build state without the need for heat treatment. On the other hand, in situ alloying or high-entropy alloys could lead to the development of new tool substrates, replacing rare and costly elements like cobalt [11]. AM offers the potential to process new alloy compositions that are not feasible with conventional sintering techniques. Thus, process-specific alloy designs for cutting tool substrates tailored to the process requirements, such as hardness, toughness, and high-temperature strength, are possible.
- Multi-material manufacturing: Multi-material processing is possible with various AM techniques. Combining different materials within a single geometry can offer favorable characteristics such as enhanced heat dissipation, damping behavior, and tool stiffness [242,243,244,245]. For example, a tough, vibration-absorbing core combined with a hard, wear-resistant outer skin could benefit milling tool carriers. Including thin heat-transmitting copper structures in the cutting wedge could enable sensor integration as well as controlled heat dissipation or heat input, either increasing or reducing the cooling of the cutting wedge during machining. This could help reduce alternating thermal loads in interrupted cutting, preventing thermal crack formation in brittle substrate materials [246].
- Increase in AM productivity and efficiency: Improvements in AM processes require innovations in process control and AM machine technology. For PBF-LB, these could include adapted scanning strategies, faster powder deposition, increased laser power, or an increased number of simultaneous lasers, as well as the intelligent use of available build volume [247,248,249,250]. Tool manufacturers aim to print AM tool carriers on conventional preforms, such as with HSK-taper [178,190,222]. This approach reduces build times, eliminates the need for referencing elements for subsequent subtractive post-processing, and limits the AM process to the geometrically complex volume area.
- Holistic economic–ecological assessment: Additional economic and ecological costs of AM can often be compensated in the use phase of the tool due to improved functionality and performance compared to conventionally manufactured tools [251,252]. However, evaluating the lifecycle costs of AM cutting tools across their entire lifecycle—from manufacturing to use—remains challenging. Optimization models can help identify ideal operating points for AM cutting tools with individualized designs, such as those optimized for the cutting fluid supply or damping characteristics. Verifying these improvements can increase the acceptance of AM cutting tools in industrial applications.
- Integrated process chain from AM to post-processing: Reliable and repeatable post-processing of the as-built tool is essential for all functional surfaces through various machining processes. To reduce individual setup efforts in the machine tool, clamping and referencing elements need to be considered during the design phase [253]. The process chain requires continuous referencing of the part in the AM machine as well as in the subsequent machining operation [254,255].
- Application of alternative AM processes: In addition to the established AM processes such as PBF, DED, BJT, and VPP, emerging AM techniques currently under research may become significant for the manufacturing of cutting tools. Tool steels have been successfully processed in low-cost FFF for tool carrier production [256]. Cold-spray AM, a solid-state powder deposition technique, shows potential for depositing steel alloys for tool carriers as well as WC-Co, ceramics, and metal–ceramic composites for tool substrates or coatings [257]. Due to its high deposition rates, flexibility in powder selection, and favorable compressive stress of the as-built part, its application in cutting tool fabrication is plausible [258,259]. However, further research is needed to identify suitable material compositions with optimal performance characteristics during machining and to evaluate the resulting tool properties, particularly in terms of wear resistance and strength.
5. Summary and Outlook
Author Contributions
Funding
Data Availability Statement
Conflicts of Interest
References
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AM Process | Advantages | Disadvantages |
---|---|---|
VPP | High geometrical complexity and accuracy; processing of metal and ceramic (composite) materials | Limited material range; green part only (sintering needed, undesired shrinkage) |
PBF | Manufacturing of dense metallic parts. Depending on the material, no need for additional heat treatment. High geometrical complexity and accuracy | Limited part size; melting process introduces residual stress; low build rate; processing of weldable materials only; high production costs |
BJT | Processing of metal and ceramic (composite) materials; low production costs; high scalability; no support structures needed | Low density; green part only (sintering needed, undesired shrinkage) |
DED | High build rate; manufacturing of dense metal parts; large build volume; high material utilization; possibility of functional graded materials | Limited geometrical accuracy and complexity; melting process introduces residual stress; processing of weldable materials only |
Steel Material | As-Built Properties | Ref. |
---|---|---|
X40CrMoV5-1 (H13, 1.2344) Conventional, heat-treated cast material | H = 540–615 HV; Rm = 1430 MPa | [66] |
X40CrMoV5-1 (H13, 1.2344) | H = 706–894 HV; Rm = 835–1236 MPa | [67,68] |
X37CrMoV5-1 (H11, 1.2343) | H = 506 HV | [69,70] |
X3NiCoMoTi18-9-5 (18Ni-300, 1.2709) | H = 333–341 HV; Rm = 1056–1096 MPa | [71,72] |
X5CrNiCuNb17-4-4 (17-4 PH, 1.4548) | H = 258 HV | [73] |
30CrNiMo8 (AISI 4340, 1.6580) | Rm = 1009–1016 MPa | [74] |
16MnCr5 (AISI 5115, 1.7131) | H = 330 HV; Rm = 1050 MPa | [75] |
18MnCrMoV4-8-7 (1.7980) | H = 405 HV | [76] |
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Kelliger, T.; Meurer, M.; Bergs, T. Potentials of Additive Manufacturing for Cutting Tools: A Review of Scientific and Industrial Applications. Metals 2024, 14, 982. https://doi.org/10.3390/met14090982
Kelliger T, Meurer M, Bergs T. Potentials of Additive Manufacturing for Cutting Tools: A Review of Scientific and Industrial Applications. Metals. 2024; 14(9):982. https://doi.org/10.3390/met14090982
Chicago/Turabian StyleKelliger, Tobias, Markus Meurer, and Thomas Bergs. 2024. "Potentials of Additive Manufacturing for Cutting Tools: A Review of Scientific and Industrial Applications" Metals 14, no. 9: 982. https://doi.org/10.3390/met14090982