Engineered design of cutting tool material, geometry, and coating for optimal performance and customized applications: A review

Cutting tool materials are the backbone of machining and play a vital role in the manufacturing industry. Innovation in cutting tools is important for customized and demanding applications. This state-of-the-art review is focused on innovations and future research directions for cutting tools covering i) tool materials/microstructure/property relationships, ii) coatings and their effect on tool performance, iii) cutting edge and functional surface preparation and effect on tool performance, iv) tool geometry for high performance and stable machining considering rapid machining, sustainability, and circularity aspects. The vision is to identify tool material/coating/geometry/functional surface relationships for significant improvement in machining performance. This paper includes perspectives from several research groups with a detailed discussion on current advances, capabilities, and challenges in engineered design of cutting tools, materials, coatings, structures and sets a new agenda for future tooling and research directions.