PRO GRESS IN NATURAL SCIENCE 　　　　　　　　　　　　　　　　　　　 　　　　　　Vol. 15 , No.

9 , September 2005

3
Cutting tool materials f or high speed machining
33
L IU Zhanqiang and A I Xing
( School of Mechanical Engineering , Shandong University , Jinan 250061 , China)

Received February 22 , 2005 ; revised March 28 , 2005

　　Abstract 　　High speed machining ( HSM) is one of t he emerging cutting processes , which is machining at a speed significantly
higher t han t he speed commonly in use on t he shop floor. In t he last twenty years , high speed machining has received great attentions as
a technological solution for high productivity in manufacturing. This article reviews t he developments of tool materials in high speed ma2
chining operations , and t he properties , applications and prospective developments of tool materials in HSM are also presented.

　　Keywords : 　tool materials , high speed machining.

　 　 High speed machining processes can produce plications for each type of t he material.
more accurate part s , as well as reduce t he cost s asso2
ciated wit h assembly and fixt ure storage by allowing
several procedures to be combined into a monolit hic
one [ 1 ] . There has been a st rong resurgence of interest
in high speed machining technology , so t hat it has
become one of t he most promising advanced manufac2
t uring technologies in t he last twenty years. High
speed machining technology has already been applied
to many manufact uring indust ries such as t he aviation
and aerospace indust ry , automobile indust ry , mould
indust ry to cut steel , cast iron and it s alloys , alu2
minum and magnesium alloys , super alloys of nickel2
based , cobalt2based , ferrous2based , titanium2based , Fig. 1. 　Variety of tool materials in high speed machining.
etc. and composite materials[ 2 ] . The applications of
1. 1 　Diamond
high speed machining are continuing to rapidly ex2
pand. Diamond has t he highest hardness , heat conduc2
tivity among t he substances and is excellent in chemi2
In order to explore t he wide applications of high
cal stability. The four types of diamonds being used
speed machining , recent develop ment s and applica2
as cutting tools are indust rial grade nat ural diamond
tions of t he tool materials in high speed machining are
( ND) , synt hetic single crystal diamond , polycrystal2
presented in t his paper.
line diamond ( PCD ) , and chemical vapor deposition
1 　Recent developments of tool materials in ( CVD ) diamond coating ( including t hin2film and
high speed machining t hick2film diamond coatings) [ 4 ] .

Many types of tool materials , ranging f rom dia2
monds to ceramics and to high speed steel ( HSS) , are
used as cutting tools in today’s machining indust ry [ 3 ]
( see Fig. 1) . It is important to be aware t hat differ2
ences in properties do exist among tool materials ( see
Table 1) , t hese differences determine t he correct ap2
Nat ural diamond is t he most expensive tool ma2
terial. Because t he ext remely sharp edge of a blade is
obtained , nat ural diamond is mainly used in some ul2
t ra2precision machinings , such as t he machining of
micro2mechanical part s , ret ro reflectors , navigating
gyroscopes , and hard disc chips , etc.

3 Supported by National Natural Science Foundation of China ( Grant No . 50375089) , Fok Ying Tung Education Foundation ( Grant No . 91054) ,
t he Natural Science Foundation of Shandong Province , China ( Grant No . Y2003 F06) , and t he Program for New Century Excellent Talents in Univer2
sity
3 3 To whom correspondence should be addressed. E2mail : melius @sdu. edu. cn

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 778 www. tandf . co. uk/ journals 　Progress in Natural Science 　Vol. 15 No. 9 　2005
Table 1. 　Main properties of some tool materials
Properties Diamond CBN
6 3
Density (10 kg/ m ) 3. 5 3. 5
Hardness ( Hv) 10000 5000
Strengt h ( kg/ mm2) — 110
4 2
Young modulus (10 kg/ mm ) 10. 5 7. 3
Thermal conductivity ( W/ m K) 2000 (single crystal) 50
　　Synt hetic single crystal diamond has good di2
mension , shape and f unction stability. It is mainly
used in machining of wood , for example , wood floor2
board coated wit h Al2 O3 .
PCD is obtained wit h some binders such as cobalt
powders by sintering under ult ra2high pressure and
high temperat ure under which condition t he diamond
is chemically safe. This sintered diamond body shows
excellent abrasion resistance wit h t he cutting of t he
nonferrous metals as well as nonmetallic material and
is taking an active part as t he high accuracy , high ef2
ficiency cutting tool for t he difficult processing sub2
stances such as t he Al2Si alloy and cemented carbide.
CVD diamond coating tools are well suited for
t he high speed machining of aluminum and ot her non2
ferrous alloys such as copper , brass , bronze , and
abrasive advanced composites such as grap hite , car2
bon2carbon , glass2fiber reinforced plastics , and car2
bon2filled p henolics[ 5 —9 ] . CVD t hin2film diamond can
be applied to such complex tool geomet ries as insert s
wit h chip breakers , solid end mills , routers , and
drills. Thick2film diamond coating tools currently
find t heir use in high speed machining of high2eutec2
tic aluminum alloys[ 10 ,11 ] .
1. 2 　CBN
Cubic boron nit ride ( CBN ) is synt hesized artifi2
cially under t he condition of t he high pressure and
high temperat ure as t he same as t he diamond. It is al2
so similar to diamond in it s polycrystalline st ruct ure
( see Fig. 2) .
CBN has small reactivity wit h t he iron system
materials and is more chemically and t hermally stable
t han t hose of t he diamond. Because of t hese proper2
ties , t he CBN has been paid attention as t he tool ma2
terial t hat is usef ul for machining of iron system ma2
terials for which t he diamond is unable.
Polycrystalline type CBN ( PCBN ) has an excel2
lent characteristic for cutting tools to machine t he cast
iron and heat resisting alloy , and t he iron system hard
© 1995-2005 Tsinghua Tongfang Optical Disc Co., Ltd. All rights reserved.
Cemented carbide Cermet Silicone nitride Alumina
14. 5 6. 8 3. 2 4. 2
1500 1600 1600 2500
250 200 120 40
60 40 3. 1 3. 6
76 13 40 20
Fig. 2. 　Structures of diamond and CBN.
materials wit h hardness greater t han HRC 45 such as
automobile part s , t he engine blocks and gears ,
shaft s , bearings. Generally speaking , PCBN machin2
ing operations should be run dry. It can be run at cut2
ting speeds above 2000 m/ min in machining of gray
cast iron materials. The largest recent growt h in t he
use of PCBN insert s is in t he area of high speed hard
machining —in particular , t he finish machining of
steel2alloy automotive engine component s , such as
gears , shaft s and bearings , which have hardness be2
tween HRC 60 and HRC 65. These part s have t radi2
tionally been ground to very tight dimensional toler2
ances and a fine surface finish.
The mechanical and t hermal properties of CBN
are influenced largely by t he kinds and addition quan2
tities of t he binders t hat are used in t he case. The
bond p hases of PCBN are Co , Ni or TiC , TiN ,
Al2 O3 , etc. The CBN grain size and bond p hase af2
fect t he PCBN machining performances. PCBN wit h
low content CBN ( 50 % —65 %) is mainly used in
finishing hardened steel ( HRC45265 ) , while high
content CBN ( 80 % —90 %) is used in high speed
rough , semi2finishing of nickel and chromium cast
iron , intermittent machining of hardened steel , hard
metal , sintered metal , and heavy alloy , etc.
The binder2less sintered CBN which does not in2
clude any binder is developed recently [ 12 —14 ] . The
binder2less CBN is synt hesized by cont rolling t he con2
dition of t he CBN particle to be fine particles having
high t hermal conductivity , excellent t hermal stabili2
 Progress in Natural Science 　Vol. 15 No. 9 　2005 　www. tandf . co. uk/ journals
ty , high hardness and st rengt h even under high tem2
perat ure. The binder2less CBN cutting tool is now
considered as t he cutting tool material of t he next
generation.
1. 3 　Ceramic cutting tool
Ceramics are non2metallic materials. Some ad2
vantages of ceramic tools are ext remely high resis2
tance to abrasive wear , cratering , and ext remely high
temperat ure hardness[ 15 ] . There are two major classes
of ceramic tool materials available : alumina ( A12 O3 ) 2
based ceramics and silicon nit ride ( Si3 N 4 ) 2based ce2
ramics.
Alumina2based ceramics has good chemical sta2
bility and low affinity wit h ferrous metals. It is t here2
fore not susceptible to adhesion. The solubility of alu2
mina in iron is only one fift h of t hat of t ungsten car2
bide ( WC) . Hence , alumina2based ceramics is wit h
low diff usion wear and very high anti2oxidization.
However , alumina2based ceramics has lower
st rengt h , f ract ure toughness , t hermal conductivity ,
and t hermal shock resistance. It has better perfor2
mance t han Si3 N 42based ceramic tools in high speed
machining of steels.
In comparison wit h alumina2based ceramics ,
Si3 N 42based ceramics has higher st rengt h , f ract ure
toughness , and t hermal shock resistance. It has a
lower t hermal expansion coefficient , Young’s modu2
lus , and chemical stability t han Al2 O32based ceram2
ics. The Si3 N 42based ceramics is not susceptible to
adhesion wit h iron. Therefore , it is mainly used in
t he high speed machining of cast iron.
Si3 N 42Al2 O3 ( sialon) ceramic tools have relatively
high st rengt h , f ract ure toughness , anti2oxidization ,
t hermal conductivity , t hermal shock resistance and
creep resistance at high temperat ures[ 16 ] . While it has
low heat expansion coefficient , sialon ceramic tools
are generally not suitable for t he machining of steels ,
it is mainly used in t he rough machining of cast iron
and nickel2based alloy [ 17 ,18 ] .
In order to f urt her improve t he performance and
wear resistance of ceramic tools to machine new work
materials and composites , whisker2reinforced [ 19 ] ma2
terials including silicon nit ride2based and alumina2
based tools , reinforced wit h silicon carbide ( SiC )
whiskers have been developed [ 20 ] . Such reinforced ce2
ramic tools are very effective in high speed machining
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779
of composites and super alloy materials used in t he
aerospace indust ry , such as nickel2based alloys , but
are not suitable for machining of cast irons and steels.
1. 4 　TiC ( N ) 2based cemented carbides
TiC ( N ) 2based cemented carbides are mostly
compose of titanium carbon nit ride ( TiCN ) wit h a
nickel or cobalt bonder [ 21 ] . They are hard and chemi2
cally stable , which leads to higher wear resistance.
Cermet s work in materials such as steels and ductile
irons t hat produce a ductile chip [ 22 ] . Their increased
speed capability enables t hem to machine carbon
steels , stainless steels , ductile irons , and cast irons at
high cutting speeds and to produce better surface finishes.
The most common cermet s are : ( 1 ) TiC2based
carbide such as TiC + Ni or Mo [ 23 ] wit h high wear re2
sistance , and TiC + TaC + WC + Co wit h high f rac2
t ure toughness , ( 2) TiN2based carbide wit h enhanced
f ract ure toughness , and ( 3 ) TiCN2based carbide
( TiCN + NbC) wit h higher wear resistance and t her2
mal shock resistance. Cermet s are very suitable for
high speed finish machining of steel alloys and cast
irons.
1. 5 　Coated tools
Performance at higher temperat ures is a goal of
many tool material developers. The answer seems to
lie in coatings added to t he tool tip to improve cutting
capabilities. Coatings include a blend of materials t hat
resist s heat and f ract ure , maintains a cutting edge ,
and st rengt hens t he bond between coating compo2
nent s and t he base materials[ 24 ] .
Two widely used coating met hods are chemical
vapor deposition ( CVD) and p hysical vapor deposition
( PVD ) [ 25 —27 ] . CVD coatings first appeared in t he
1970s[ 28 ] . This process is carried out in a vacuum
chamber in which t he coating material is applied to a
tool by vacuum sputtering or arc2evaporation. Initial2
ly t he coating was carbide , t hen titanium nit ride , fol2
lowed by titanium carbon nit ride and aluminum ox2
ide . Today CVD2coated , cobalt2enriched insert s will
be used in 40 % —50 % of general machining opera2
tions. The PVD coating process is similar to CVD but
can be carried out at around 500 ℃ ( as opposed to
1000 ℃) , and does not adversely affect steel. PVD
was initially developed for HSS and later applied to
carbide [ 29 ] . Wit h t he CVD process , most coatings are
multilayers. Wit h PVD , bot h mono and multilayer
coating [ 30 —34 ] processes are feasible.
 780 www. tandf . co. uk/ journals 　Progress in Natural Science 　Vol. 15 No. 9 　2005

The t hree coatings most widely used today are ti2 ing materials by applying such ceramic coating to t he
tanium nit ride ( TiN ) , which was int roduced in t he tools[ 44 ,45 ] .
1980s , titanium carbonit ride ( TiCN ) [ 35 —38 ] , and ti2
tanium aluminum nit ride ( TiAlN ) [ 39 —43 ] . TiN is New hard coatings have recently been developed
considered a good general2purpose coating and is easi2 such as PVD of carbon nit ride ( CNx) , nit ride ( TiN/
ly recognized by it s gold color. The advantages of NbN , CrN [ 31 ] , TiN/ VN ) , DL C ( diamond like car2
TiN coating are increased surface hardness , increased bon coatings ) [ 46 —48 ] , CBN coating [ 49 ] etc. These
tool life , better wear resistance , and higher lubricity , coatings have good t hermal stability under elevated
which provides less f riction and reduces edge build2 temperat ure and will be widely used in high speed
up . TiN coating is mostly recommended for machin2 machining.
ing low alloy steel and stainless steel. TiCN coating is
PVD/ CVD coatings are also combined in t he
gray colored , and even harder compared to TiN . It s
same coating/ subst rate system. An underlying CVD
advantages are increased cutting speed and feeds
layer can provide exceptional adherence to t he sub2
( 40 % to 60 % higher compared to TiN ) , greater
st rate , while t he smoot h PVD outer layer permit s
metal removal rates , and superior wear resistance.
higher cutting speeds and lower cutting forces.
TiCN coatings are recommended for machining all
material types. TiAlN coating appears gray or black Nano2coatings are made of hundreds of layers
and is primarily used to coat carbide. It can work at t hat are only a few nanometers t hick[ 50 ,51 ] . Nano2
very high temperat ures ( 800 ℃) , which makes it sized2coating composites promise high temperat ure
ideal for high speed machining wit hout coolant . Pres2 hardness , st rengt h and f ract ure toughness since t hey
surized air is recommended to remove chips f rom t he have a greater number of grain boundaries , which is
cutting zone. It works well on hardened steels , tita2 directly related to t he decreased size of each grain.
nium and nickel alloys , as well as abrasive materials The hardness for nano2coatings measures about 2800
like cast iron. to 3000 on t he Vickers scale and exhibit s a 5 to 50
percent increase in wear resistance compared to mate2
Because ceramics has many excellent properties
rial made of submicron powders. It has been reported
such as t he wear resistance , t hermal resistance , cor2
t hat grades wit h 62 alternating layers of titanium car2
rosion resistance , it becomes possible to make t he u2
bide ( TiC) and titanium carbon nit ride have been de2
nique composite material t hat combines t he excellent
veloped.
advantage of t he base material and ceramics by coat2
ing of t he ceramics. It improves tool life more sub2 The most commonly used coatings for machining
stantially by t he reduction of wear resistance , f riction of steels and cast irons available on t he market are
coefficient in comparison wit h t he conventional coat2 specified in Tables 2 and 3 , respectively.
Table 2. 　Specification of t he selected coatings for steel
Coating structure Recommended applications Notes
I. Universal grades
PVD2TiN on a very tough micrograin Used for all P , M , and K groups of materials Especially for high quality t hreading
CVD2TiC/ TiCN/ TiN Wit h a wide field application for steels Low and medium cutting speeds
CVD2TiCN/ TiN2TiC2TiCN/ Al 2O 3/ TiN First choice for steels and most types of ma2 Combines good wear resistance wit h high
chining operations toughness
CVD2TiCN/ Al 2O 3/ TiN wit h t hick ceramic Wit h a wide field application for steels Can be used for cast iron
layer and cobalt2enriched substrate
CVD2TiC + TiCN/α2Al 2O 3 wit h t hick ceramic For finishing and medium roughing of carbon The most wear2resistant of universal grades
layer and alloy steels
CVD2Al 2O 32Ti ( N , B ) wit h multiple ceramic High2speed turning of carbon steels and stain2 Improved oxidation and adhesion resistance
layer less alloys
II. Coating for specific machining application
CVD2TiCN/ TiC/ Al 2O 3 For stainless steels Minimizes tendency to built2up edge
CVD2TiCN / Al 2O 3/ TiN on tough substrate For steels and stainless steels in interrupted cuts Excellent wear resistance and improved tough2
wit h a cobalt2enriched zone ness
To be continued

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 Progress in Natural Science 　Vol. 15 No. 9 　2005 　www. tandf . co. uk/ journals 781

Continued
Coating structure
CVD2TiCN / Al 2O 3/ TiN on hard substrate
wit h a cobalt2enriched zone
CVD2TiN / Al 2O 3/ TiCN/ TiC/ TiCN/ TiN on
cobalt2enriched carbide
PVD2TiAlN on micrograin substrate
PVD2TiAlN/ TiN on cermet substrate
PVD2TiN on brazed CBN tips
PVD2TiAlN on brazed CBN tips
Recommended applications
Dry cutting at cutting speeds higher t han
300 m/ min
For heavily interrupted cuts
For finish milling mold and die steels at speeds
of 120 —150 m/ min
For finishing and medium operations in wet and
interrupted cutting
For high precision turning of hardened steels at
high speeds
For high2speed continuous to medium inter2
rupted turning of hardened steels
Notes
Highest t hermal resistance
Highest toughness
On solid square end mills and ball2nose end
mills
Thermal shock and fracture resistance
Smoot h coating enhances edge strengt h and
wear resistance
Excellent wear resistance and extended tool life

Table 3. 　Specification of t he selected coatings for cast irons

Coating structure Recommended applications Notes
CVD2 TiCN/ Al 2O 3/ TiN wit h t hick TiCN For turning spheroidal and gray cast irons. The same High wear and t hermal resistance
and Al 2O 3 layers coating on tough substrate is for heavy operations
CVD2TiCN/ 2 (Al 2O 3/ TiN For turning cast iron at high speeds Includes t hickα2Al 2O 3 and t hinκ2Al 2O 3 layers
CVD2TiCN/ Al 2O 3 on hard substrate For turning and grooving gray cast iron at high speeds Excellent flank wear resistance
CVD2TiN/ Al 2O 3/ TiN on special sub2 For ductile cast irons at cutting speeds up to 200 m/ Improved adhesion resistance , ultrafine Al 2O 3
strate layer min layer
Solid CBN coated wit h TiN High2speed machining of pearlitic gray cast iron. First Optimum wear resistance
choice for chilled cast iron
Si 3N 4 ceramic coated wit h TiN and Universal grade for cast iron in continuous cuts at high Can be used wit h or wit hout coolant
Al 2O 3 speeds

　　In cont rast wit h t he above hard coatings , coat2
ings on high speed steel such as sulfides ( MoS2 ,
WS2 ) are referred to as soft coatings[ 52 —55 ] . They are
mainly used in t he high speed machining of high
st rengt h aluminum alloy , titanium alloy and some
precious metals.
1. 6 　Ult ra fine grain carbide
WC carbides wit h 0. 2 —1μm grains , added wit h
TaC , NbC , etc. having higher hardness ( HRA 90 —
93 ) and st rengt h ( 2000 —3500 M Pa , up to
5000 M Pa) , can easily be fabricated to solid tools and
insert s and be applied to high speed machining of fer2
rous2based , nickel2based , and cobalt2based high tem2
perat ure alloys , titanium2based alloys , t hermal resis2
tant stainless steels , welded materials , and super hard
materials[ 56 ] .
1. 7 　Power metal high speed steel
Originally cutting tools were simply made f rom
t he hardest steel alloy anyone could find. Event ually
certain alloy steels became known as high2speed steel
( HSS) . These steels are still widely used for round
body tools ( drills , reamers , and end mills ) . Ma2
chines cutting at low speeds can more economically
use HSS. Over t he last 20 years , HSS has been made
f rom powder metal ( P/ M ) , which allows manufac2
t urers to use alloys and develop microst ruct ures t hat
cannot be produced by conventional forging metallur2
gy [ 57 ] . These materials are much harder t han conven2
tional HSS , allowing faster cutting and providing t he
ability to cut harder materials.
2 　 Prospective of cutting tool materials in
high speed machining
Wit h respect to t he main cutting tool materials
( carbides and t heir related coatings , cermet s , ceram2
ics , PCBN , and diamonds) in high speed machining ,
t he following t rends are predictable : ( 1 ) Carbides :
develop ment of carbides has been mat ure. Progress
will continue in binder enrichment techniques which
result in increased cutting edge security and wider
range of application. ( 2 ) Hard coatings : progressing
f rom CVD ( approximately 50 % of t he coatings in use
today) to PVD ( most rapidly growing coating) offers
t he ability to coat a sharp edge. New coating materi2

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 782 www. tandf . co. uk/ journals 　Progress in Natural Science 　Vol. 15 No. 9 　2005
als include TiAlN and TiB2 by PVD techniques , and
application of soft lubricious coatings such as MoS2
and WC/ C over PVD TiN or TiAlN mostly for
drilling and dry drilling applications will be devel2
oped. ( 3 ) Develop ment continues on advanced coat2
ings such as CBN , which will offer t he same increases
in productivity in ferrous machining as already com2
mercially available diamond coatings in non2ferrous
applications. ( 4) Cermet s : newer develop ment s com2
bine excellent resistance to deformation and chemical
wear wit h a degree of toughness t hat enables t hem to
be used in semi2finishing as well as finishing opera2
tions. Coatings f urt her enhance t he performance of
t hese modern cermet s. ( 5) Ceramics : advances in sil2
icon nit ride ceramics have expanded t heir application
range f rom nickel2based alloys to cast irons. CVD
coatings on t hese materials have expanded t heir appli2
cation to ductile iron workpieces. In t he aerospace in2
dust ry a new breed of alumina ceramics st rengt hened
by silicon carbide whiskers is significantly enhancing
productivity in t he machining of inconel and similar
high st rengt h high temperat ure alloys.
3 　Conclusions
High speed machining technology has become
one of t he most promising advanced manufact uring
technologies. Tool materials play an important role in
high speed machining technology. The available tool
materials for high speed machining are reviewed in
t his paper. As t his HSM t rend continues , t he cutting
tool providers must keep pace by providing cutting
tool materials t hat can operate at t he elevated cutting
speeds.
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