toolcut

Toolcut is a term used in manufacturing and toolmaking to denote the process of removing material with a cutting tool to establish a defined geometry on a workpiece. The term is used across metalworking, woodworking, and plastics machining to describe both rough shaping cuts and subsequent finishing cuts that set tolerances and surface finish.

Definition and scope: A toolcut refers to the operation where a cutting tool engages material along a planned path to remove material, creating edges, slots, or faces with controlled dimensions. It can involve end mills, turning tools, saw blades, or carbide inserts, and may be performed on CNC machines or by manual setups.

Process and parameters: Key factors include tool selection, material type, cutting speed, feed rate, depth of cut, and coolant use. Good practice minimizes tool wear, burr formation, and heat buildup while achieving the required surface finish and dimensional accuracy. After cutting, parts are deburred and measured against tolerances with calipers, micrometers, or CMM when needed.

Applications: Toolcut is used in toolmaking to shape tool blanks, in fixture and component fabrication, and in hobbyist projects where precise edges or pockets are required. In production, toolcuts are often integrated into larger machining plans with defined process sheets.

Variants and related terms: Rough-cut describes a first-pass toolcut that removes the majority of material; finish-cut provides the final dimension and surface quality. Related concepts include facing, pocketing, and grooving.

Quality and safety: Proper PPE and machine guarding are essential. Workholding must be secure; cutting parameters should be chosen to maintain tool life and workpiece integrity.