Case Study | High-Efficiency & Proven Machining with Special-Purpose Cutting Tools – 3 Key Improvements
In a machining workshop, the drilling of a batch of critical components ran into serious difficulties due to frequent tool wear and chip jamming caused by built-up edge and aluminum sticking. Production efficiency dropped sharply, while manufacturing costs surged. How could this bottleneck be overcome?
With the engineering support and customized solutions from Aoshiji® Custom Tools, the manufacturer was able to break through this challenge, significantly improving tool life and machining stability while reducing overall production costs.In challenging aluminum machining environments, special-purpose cutting tools play a critical role in stabilizing chip control, preventing built-up edge, and maintaining machining accuracy.
The customer reported that the special-purpose cutting tool frequently experienced aluminum built-up edge and chip jamming during machining, which severely affected production efficiency and product quality. The machining parameters were: spindle speed S1300–S2100 and feed rate F600–F1000.
Complex operating conditions with multiple influencing factors were identified:
Excessive Runout: The special-purpose cutting tool was clamped to the toolholder with screws, resulting in runout values exceeding the normal range (0.02–0.05 mm). This negatively affected machining accuracy, accelerated tool wear, and became one of the potential causes of aluminum built-up edge and chip jamming.
Large Stock Allowance on the Workpiece: The blank dimension at the part opening had an excessive allowance. The larger stock removal increased the cutting load on the tool, making chip clogging and tool jamming more likely.
Differences Between New and Old Machines: The same tool performed differently across various machines. Variations in machine precision and stability posed challenges for tool adaptability, adding uncertainty to the machining process.
Insufficient Internal Coolant Pressure: Although the required internal coolant pressure for the special-purpose machine was 30 bar, the actual pressure reached only about 18 bar. The insufficient coolant supply failed to provide effective cooling and chip evacuation, resulting in excessive tool temperature, chip adhesion, and ultimately aluminum sticking and tool jamming.
As a result, the manufacturer urgently needed more reliable special-purpose cutting tools to stabilize chip evacuation and extend tool life under demanding aluminum machining conditions.
Before the tool improvement, the machining process suffered from severe chip control issues:
Excessive aluminum chip accumulation not only clogged the tool and caused jamming, but also disrupted machining continuity.
After machining, operators had to manually remove the aluminum chips, which increased labor costs, reduced production efficiency, and made it difficult to ensure consistent product quality.
External Support: Aoshiji® Custom Tools immediately dispatched on-site engineers to monitor the machining process, gather real-time feedback, and document the findings.
Internal Response: A dedicated technical task force was quickly assembled to analyze influencing factors and identify the root causes of the issue.
Improvement Plan: The team confirmed the corrective solution and rapidly optimized the tool cutting-edge geometry.
Trial Validation: Test cuts were carried out to verify the improvements, effectively resolving the chip control problem and ultimately overcoming a long-standing challenge for the customer.
Internal Actions: A dedicated technical task force was quickly assembled to analyze the influencing factors, identify the root causes, and establish clear problem points. The team confirmed the improvement plan, rapidly optimized the tool cutting-edge geometry, and carried out trial cuts. The solution effectively resolved the chip control issues and ultimately overcame a long-standing challenge that the customer had been unable to solve.
Significant Improvement in Chip Control: After optimizing the cutting-edge geometry, chips were able to break and evacuate smoothly during machining, eliminating clogging issues. Post-improvement machining photos clearly show fine, short chips, effectively preventing aluminum chip accumulation and ensuring a stable, uninterrupted cutting process.
Meeting Customer Requirements: Following two to three months of on-site monitoring and feedback, the improved tool fully met the customer’s tool life expectations. The customer expressed strong recognition of the performance of Aoshiji® Custom Tools, establishing a solid foundation for continued cooperation.
Performance Advantages of Special-Purpose Cutting Tools
In this case, we have seen the complexity of machining challenges under multiple influencing factors, as well as the effectiveness of targeted improvement measures. When facing similar issues, it is essential to conduct in-depth root cause analysis in order to develop practical and sustainable solutions. At the same time, continuous exploration and experimentation by the technical team play a critical role in problem-solving. By optimizing tool geometry and structure, tool performance can be significantly enhanced to fully meet production demands.
This case also proves that choosing the right special-purpose cutting tools is essential for maintaining machining stability, extending tool life, and preventing chip-related failures in high-volume production.
At Aoshiji® Custom Tools, we provide proven machining solutions backed by high-efficiency and high-precision equipment. Whether for standard machine tools or dedicated special-purpose machines, for complex custom tools or challenging machining conditions, we are ready to deliver the right cutting tool solution. From design to manufacturing, every stage is strictly controlled by our professional team. With advanced craftsmanship and dedicated service, we deliver cost-effective tooling solutions that ensure both performance and reliability.
By combining optimized tool geometry, stable process parameters, and application-based engineering support, special-purpose cutting tools provide manufacturers with higher reliability, longer tool life, and consistent machining quality across complex production scenarios.
For more insights into precision tooling, you can also explore our products such as Custom Reamers for High-Precision Machining and Step Reamers for Complex Hole Processing.
To stay updated with industry perspectives, see reports like Global Cutting Tool Market Trends 2025 and Latest CNC Machining Technology Insights.
Choose Aoshiji® Custom Tools — eliminate tool compatibility concerns and unlock a new level of high-efficiency machining with our integrated solutions.
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Regarding chipbreaker groove design, please refer to:
