Cutting Tool Materials: Properties & Applications Guide

Alia Afifah — Thu, 29 Dec 2022 07:39:29 +0000

Cutting tools are an essential part of manufacturing processes.

They are used in a variety of industries, including metalworking and woodworking.

However, different cutting material types have unique cutting tool properties—such as strength, toughness, and wear resistance—that make them suitable for specific tasks.

So, it’s important to know what each material is capable of before choosing which one you want to use for your project.

Below is a cutting tools list based on the most commonly used tool materials used in machining.

Types of Cutting Tool Materials

Carbon

Carbon is one of the most common cutting tool materials, and for good reason.

It is easy to machine and is relatively inexpensive.

Moreover, carbon is tough, but not as tough as tungsten carbide or diamond.

However, carbon’s main drawback is its brittleness.

If not properly heat treated after machining, carbon can crack easily under stress or sudden impact loads.

High-speed steel (HSS)

High-speed steel (HSS) is a type of tool steel that has been hardened through the use of alloying elements.

The main alloying element in HSS is tungsten, which increases the cutting speed and strength of the steel.

Hence, high-speed steels are ideal for creating cutting tools that are used under high pressure, high temperature, and high-speed conditions.

Cemented carbide cutting tool materials

Cemented carbide is a composite cutting material made from tungsten, tantalum, and titanium carbide with cobalt as the binder.

It is suitable to use in applications where extreme durability, wear resistance, and high strength are needed.

It is also resistant to corrosion at high temperatures and is perfect for use in extreme environments like aerospace applications or oil refineries.

Ceramics

Ceramics are strong and durable, but they can also be brittle.

They are very good at withstanding high temperatures, which makes them ideal for cutting tools used in metalworking processes like welding or brazing.

Furthermore, their low thermal expansion coefficient makes them a good choice for use in extreme temperatures.

When it comes to wear resistance, ceramics tend to be less durable than metal or polymers.

But they are still one of the best materials for cutting tools because they are resistant to corrosion.

Cubic boron nitrate (CBN)

Cubic Boron Nitride (CBN) is the second hardest cutting material after diamond. Known for its extreme hardness, CBN is a popular choice in the tool industry.

The reason is that it has a high hardness rating and is perfect to create cutting tools that are hard, but also brittle.

This means that it is difficult to create a sharp edge on these tools, but they will last for a long time before needing to be replaced.

Diamond cutting tool materials

Diamond is the hardest material and the most expensive.

It offers outstanding cutting tool properties including high thermal conductivity, exceptional abrasion resistance, and minimal thermal expansion.

Diamond is ideal for machining very hard materials such as carbides, nitrides, and glass.

Moreover, diamond cutting tools give a good surface finish and dimensional accuracy.

However, they are not so recommended for machining steel.

Comparison of Industrial Cutting Tool Materials

Different cutting tool materials offer unique advantages depending on machining conditions, workpiece materials, cutting speed and required surface finish.

The table below compares the most commonly used cutting tool materials in precision machining.

Material	Best Application	Temperature Resistance	Typical Workpiece
PCD	High-volume non-ferrous machining	High	Aluminium, composites
CBN	Hardened steel machining	Very High	Hardened steel, cast iron
MCD	Ultra-precision finishing	Medium	Optical parts, lenses
Carbide	General CNC machining	Medium	Steel, stainless steel
Ceramic	High-speed dry cutting	Extremely High	Cast iron, superalloys
HSS	Low-speed machining	Low	Soft metals, general use

Frequently Asked Questions About Cutting Tool Materials

What are the most common cutting tool materials?

The most commonly used cutting tool materials are High Speed Steel (HSS), cemented carbide, ceramics, cubic boron nitride (CBN), polycrystalline diamond (PCD), and monocrystalline diamond (MCD). Each material has different hardness, toughness, and thermal resistance properties suited to specific workpiece materials and machining conditions. Carbide is the most widely used for general CNC machining, while PCD and CBN are reserved for high-precision or high-volume applications.

Which cutting tool material is best for machining aluminium?

PCD (Polycrystalline Diamond) is the preferred cutting tool material for machining aluminium and aluminium alloys. PCD offers extremely low friction, high wear resistance, and produces excellent surface finishes on non-ferrous materials. It is widely used in the automotive industry for machining aluminium engine components, transmission housings, and wheels. MCD (Monocrystalline Diamond) is also used for ultra-precision optical and mirror-finish aluminium applications.

What is PCD and when should it be used?

PCD stands for Polycrystalline Diamond — a synthetic diamond material produced by sintering diamond particles under high pressure and temperature. PCD cutting tools are used when machining non-ferrous metals (aluminium, copper, brass), composites (CFRP, GFRP), ceramics, and graphite. PCD is not suitable for machining ferrous metals (steel, cast iron) because carbon in diamond reacts chemically with iron at high cutting temperatures. PCD tools offer tool life 10–100x longer than carbide in suitable applications.

What is the difference between PCD and CBN cutting tools?

PCD (Polycrystalline Diamond) and CBN (Cubic Boron Nitride) are both superhard tool materials, but they target different workpiece materials. PCD is used for non-ferrous metals, composites, and ceramics — it reacts with iron and cannot be used on steel. CBN is used specifically for hardened ferrous metals — hardened steels, cast iron, and superalloys — where PCD would fail. In summary: use PCD for aluminium and composites; use CBN for hardened steel and cast iron.

What is MCD (Monocrystalline Diamond) and how is it different from PCD?

MCD (Monocrystalline Diamond) is a single-crystal natural or synthetic diamond used as a cutting tool material for ultra-precision machining. Unlike PCD, which consists of randomly oriented diamond particles, MCD has a continuous crystal structure that allows it to achieve cutting-edge sharpness at the nanometre level. MCD is used for mirror-finish machining of optical components, lenses, semiconductor wafers, and reflective surfaces where surface roughness Ra below 10nm is required. MCD tools are more expensive and more brittle than PCD.

Are diamond cutting tools suitable for machining steel?

No — diamond cutting tools (PCD and MCD) are NOT suitable for machining steel or other ferrous metals. At the high temperatures generated during steel cutting, the carbon atoms in diamond react chemically with the iron in steel, causing rapid tool wear (a process called graphitisation or carbonisation). For hardened steels and cast iron, CBN (Cubic Boron Nitride) cutting tools should be used instead. For soft steels and general ferrous machining, carbide inserts are the standard choice.

How long do PCD cutting tools last compared to carbide?

PCD cutting tools typically last 10 to 100 times longer than carbide tools in suitable non-ferrous machining applications. For example, in high-volume aluminium machining, a PCD insert may complete 50,000–100,000 parts before replacement, compared to 500–2,000 for carbide. The higher initial cost of PCD is offset by significantly lower cost-per-part, reduced downtime for tool changes, and more consistent dimensional tolerances over the tool’s life. PCD is most cost-effective in high-volume, continuous production environments.

How do I choose the right cutting tool material for my application?

Choosing the right cutting tool material depends on four main factors: (1) Workpiece material — ferrous metals require CBN or carbide; non-ferrous metals and composites suit PCD or MCD; (2) Required surface finish — ultra-precision optical finishes need MCD; (3) Production volume — high-volume production justifies PCD/CBN investment; (4) Cutting conditions — interrupted cuts and vibration require tougher materials like carbide or CBN. Asime’s engineering team provides free application consultations to recommend the optimal tool material for your specific machining requirements. Contact us at +603-8065 3871 or via the form below.

Custom Cutting Tools for Your Machining Requirements

The performance, longevity, and accuracy of a cutting tool are directly dependent on the quality and its materials.

At ASIME, we offer excellent custom tooling solutions to meet the demands of industries like automotive, aerospace, electronics, and general manufacturing.

Whether you’re working with metals, composites, or ceramics, we provide expert guidance on tool materials used in machining to ensure the best outcomes for your project.

Are you ready to make your own custom cutting tools? Contact us right away!

Need help? Get your FREE consultation NOW.

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