CUTTING THROUGH THE TOUGH

As aerospace manufacturing increasingly relies on high-performance alloys and composites, innovative cutting tool technologies are helping industry overcome the challenges of machining difficult-to-cut materials.

- By Team ET Now Machinist

The aerospace industry has long depended on materials that can withstand extreme stress, temperature, and environmental conditions. But these very properties like high strength, hardness, and resistance to heat make such materials notoriously difficult to machine. From titanium and nickel-based superalloys to composites and high-strength steels, these "tough-to-cut" materials test the limits of cutting tools and production efficiency.

These materials are essential for modern aircraft: high-strength steels for landing gear and fasteners, titanium alloys for lightweight, corrosion-resistant engine components, and heat-resistant superalloys for the hot sections of jet engines. Composites, meanwhile, have revolutionized airframe and stealth designs by reducing weight while maintaining strength. Yet, each material presents its own set of machining problems—high cutting forces, extreme heat generation, poor thermal conductivity, and rapid tool wear. Titanium’s “springiness” causes vibration and accuracy issues, while composites risk delamination during machining.

With aerospace manufacturers increasingly adopting advanced alloys and hybrid materials, the pressure is on toolmakers to keep up. Although CNC machines and CAM systems have evolved rapidly, the cutting tool—the final, most critical link in the production chain—has advanced more conservatively. To manage these challenging materials, manufacturers often slow machining speeds, sacrificing productivity and raising costs. Even incremental advances in tool design or materials can make a big difference.

Modern cutting tools must be hard, durable, and precise to achieve high productivity while maintaining tool life and part accuracy. This requires innovation in three key areas: cutting material grades, tool design, and digital integration.