RFID Management of Turning Tools: Application throughout the entire lifecycle of turning tools (external turning tools, internal turning tools, and threading tools)

This article introduces how RFID technology is applied to turning Tools, focusing on typical turning tools such as **external turning tools, internal turning tools, and threading tools**. To differentiate it from previous articles on milling tools, this article will explore the unique applications of RFID in **separate management of tool body and inserts**, **external pre-setting and rapid in-machine tool setting**, and **dynamic optimization of cutting parameters**, starting from the **special characteristics of turning machining** (such as continuous cutting, frequent insert changes, and extremely high precision requirements).

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# The "Digital Twin" of Tool Body and Inserts: Innovative Applications of RFID Technology in Intelligent Management of Turning Tools

In the field of turning machining, **external turning tools**, **internal turning tools**, and **threading tools** are the three core tools. They are responsible for the contouring of rotating parts, precision machining of internal cavities, and cutting of thread elements, respectively. Unlike the multi-tooth intermittent cutting of milling, turning is usually **single-point continuous cutting**, which means that the main cutting edge of the tool is subjected to continuous friction, high temperature, and impact. This machining characteristic places extremely high demands on the precision retention of cutting tools, the accuracy of insert replacement, and the rationality of cutting parameters.

However, traditional turning tool management has long faced two major structural challenges: **first, the separate management of the "tool body" and "inserts."** The tool body, as a high-value component, can be used for a long time, while inserts, as consumables, are frequently replaced, often resulting in a disconnect between their matching relationships and historical data; **second, the time-consuming "in-machine tool setting."** After each insert or tool body replacement, the operator must re-set the tool on the machine and input tool offsets, consuming valuable cutting time. The deep application of RFID technology is bringing a completely new solution to turning tool management.

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### I. The "Dual Identity" Binding of Turning Tools: From Separation to Unification

The structural uniqueness of turning tools lies in the fact that a complete turning tool typically consists of two parts: a **tool shank (tool body)** and a **indexable insert**. In the traditional model, the tool shank is managed as a fixed Asset, while the insert is managed as an auxiliary material, and the information linking the two often relies on paper records or manual memory.

**RFID solution: Building a Digital Twin of Tool Holder and Insert**

1. **Tool Holder Coding**: An industrial-grade anti-metal RFID tag is embedded in a non-interference area (such as the side or bottom of the tool holder) of each external turning tool holder, internal boring tool holder, or thread turning tool holder through milling or drilling. This tag Stores static information about the tool holder: tool holder model, material, recommended overhang length, purchase date, and work section.

2. **Insert Association**: RFID turnover tags are placed on the insert packaging or transfer tray. When an operator takes out a box of new inserts and installs them onto the tool holder, the dynamic information of the insert (ISO code, coating type, tip radius, preset life) is associated with the tool holder tag using an RFID Reader.

3. **Unified File**: From this point on, the tool holder and its currently installed insert are considered a unified "turning unit". When the tool holder tag is read subsequently, the system not only knows "this is an external turning tool," but also "it is currently equipped with a certain type of insert and has been cutting for how many minutes."

### II. External Pre-setting and In-Machine Rapid Loading: Making Tool Changes "Zero Waiting Time"

In turning machining, tool changes (whether replacing worn inserts or replacing the entire tool holder for different processes) involve tedious tool compensation measurements. The integration of RFID with tool setting devices and machine tool control systems automates this process.

**Application Scenario: Rapid Change of External Turning Tools**

1. **External Pre-setting:** In the tool pre-setting room, the operator places an **external turning tool** equipped with a new insert on a tool setting device with RFID read/write functionality. The tool setting device automatically identifies the tool holder tag and retrieves the standard parameters of the tool holder. After the operator completes the tool setting measurement, the system directly writes key data such as the **measured tool tip coordinates (X, Z axis offset) and tool tip radius** onto the RFID tag on the tool holder.

2. **In-machine loading:** The operator loads the pre-adjusted cutting tool into the turret of the CNC lathe or turning center. An RFID reader installed near the turret automatically identifies the tool tag.

3. **Automatic data transmission:** The reader automatically transmits the latest tool compensation data from the tag to the CNC controller (such as Fanuc or Siemens systems) via an industrial bus (e.g., OPC UA). The machine tool does not need to wait for the operator to manually input parameters; the tool can be immediately put into machining, reducing tool change time by more than 50% and eliminating the risk of manual decimal point errors.

### III. Threading Tool "Error Prevention" and "Lifespan Segmentation Management"

Threading is one of the most demanding processes in turning. The tip shape of the threading tool must strictly match the thread profile required by the workpiece. Incorrect tool installation will render the entire workpiece unusable.

**RFID Error Prevention and Verification** When the operator loads a threading tool into the turret, the RFID system automatically reads the "thread type" (e.g., metric 60°, imperial 55°, trapezoidal thread) and "pitch range" stored in the tool holder tag. The system compares this information with the thread parameters set in the current machining program. If the operator mistakenly loads a tool suitable for turning M30×3.5 threads, while the program requires M30×1.5 fine threads, the system will immediately issue an audible and visual alarm or lock the spindle to prevent quality issues at the source.

**Segmented Lifespan Management** For expensive threading tools (especially solid thread cutters or form cutters), the RFID system supports "segmented lifespan management." For example, if the total lifespan of a threading tool is set to 100 parts, the system divides it into three stages:

- **New Tool Stage (1-30 parts)**: Used for roughing or less demanding operations.

- **Stable Stage (31-70 parts)**: Used for finishing.

- **Wear Stage (71-100 pieces)**: Degraded for chamfering or deburring.

RFID tags record the current "number of pieces processed" and "stage" in real time, ensuring the tool performs at its maximum value under appropriate working conditions.

### IV. The "Invisible" Management Challenges of Internal Bore Turning Tools

Drying tools (internal turning tools) have a concealed machining area, making it difficult to directly observe the tool's condition within the hole (e.g., vibration, chip removal). Furthermore, the slender internal bore turning tool holders are valuable and prone to breakage.

**Integration of RFID and Sensing Technology**: Cutting-edge intelligent internal bore turning tool solutions are beginning to integrate **micro-strain gauges or vibration sensors** inside the tool holder, using RFID technology for wireless energy and data transmission.

- **Real-time Status Monitoring**: During boring, sensors detect the vibration amplitude and cutting force of the tool tip in real time. When the vibration exceeds a threshold, an "abnormal status bit" within the RFID tag is triggered.

- **Tool Breakage Warning:** When the tool returns to the tool change position, the reader on the machine tool side detects this abnormal status. The system can automatically adjust the feed rate for the next cut or directly stop the machine and issue an alarm, preventing the entire workpiece from being scrapped due to the internal tool breaking inside.

### V. A Future-Oriented Data Ecosystem for Turning Tools

The application of RFID technology in turning tools is building a complete data closed loop covering **tool design, procurement, warehousing, use, regrinding, and scrapping**.

- **For the Purchasing Department:** RFID-recorded tool life data becomes the most objective basis for evaluating the cost-effectiveness of different brands of inserts.

- **For the Process Department:** By analyzing the cutting time and tool change frequency of different tools in the same process, cutting parameters can be optimized, and machining cycle time improved.

- **For the Production Workshop:** "Paperless" tool management is achieved; operators only need to scan the tool holder to obtain all the necessary information.

**Conclusion**

From the contouring of external turning tools to the deep cavity machining of internal turning tools, and the precision meshing of threading tools, RFID technology is infusing these turning tools with "digital genes." By solving the problem of separate management of the "tool holder and insert," and establishing a data link between external pre-adjustment and internal loading, RFID enables precise error prevention for threading tools and concealed status sensing for internal turning tools. RFID makes turning more transparent, efficient, and reliable. When every turning tool can "speak," the future of precision turning will move towards a completely new intelligent dimension.