Mitsubishi Materials has introduced an advanced cutting tool manufacturing technology that utilizes lasers, significantly enhancing precision machining across various industries such as automotive and electronics. Traditionally, grinding tools have been used to shape cutting tools, but this method has limitations in terms of miniaturization and accuracy.
According to Mitsubishi Materials, the conventional approach involved mechanical processing using grinding wheels. However, these wheels face constraints when it comes to reducing the size of the cutting tools. Additionally, when working with tough materials like CBN (cubic boron nitride) sintered bodies or diamond, only specific grinding wheels can be used. This often leads to rapid wear and deformation of the grinding wheel, making it difficult to maintain the required dimensional accuracy of the final product.
To address these challenges, Mitsubishi Materials has developed a laser-based cutting tool processing technology. This innovative method uses concentrated laser beams to achieve a much smaller focal diameter—often below tens of micrometers—which is not feasible with traditional machining techniques. Unlike grinding wheels, the laser does not experience wear during the process, eliminating the need for frequent adjustments. Moreover, since no external force is applied during machining, there is no risk of introducing strain into the workpiece, ensuring high dimensional accuracy.
This technology allows for both planar and three-dimensional machining of hard-to-process materials. It enables the creation of cutting tools with complex shapes and extremely fine cutting edges, which were previously difficult to achieve. The ability to produce free-form designs with precision opens up new possibilities in tool manufacturing.
In the future, Mitsubishi Materials plans to incorporate this laser technology into its range of cutting tools, particularly for small-diameter end mills that utilize CBN sintered bodies. This advancement is expected to improve efficiency, reduce costs, and enhance performance in demanding industrial applications.