Recent Advances and Future Trends in Cutting Tool Materials for Metal Cutting Applications

The performance of metal cutting processes significantly depends on selecting and applying suitable cutting tool materials. This review presents a comprehensive overview of both conventional and advanced materials, including High-Speed Steels (HSS), cemented carbides, ceramics, Cubic Boron Nitride (CBN), and Polycrystalline Diamond (PCD) with a focus on their mechanical strength, thermal stability, wear resistance, and cost-effectiveness. Recent developments such as nanocomposite coatings, additive manufacturing, and hybrid machining methods are examined for their potential to enhance tool life and machining efficiency. Emphasis is also placed on sustainable manufacturing approaches through cryogenic cooling, Minimum Quantity Lubrication (MQL), and eco-friendly cutting fluids. Furthermore, integrating smart technologies like real-time monitoring, digital twins, and AI-driven optimisation is discussed as a key enabler of next-generation machining. This review aims to guide future innovations toward high-performance, cost-efficient, and environmentally sustainable cutting tool solutions. Major Findings: Recent advancements in cutting tool materials, such as nanocomposite coatings, hybrid tool compositions, and additive manufacturing, have significantly improved wear resistance, tool life, and machining precision. Environmentally sustainable practices like minimum quantity lubrication, cryogenic cooling, and the use of biodegradable fluids are gaining traction for greener manufacturing. Additionally, the integration of smart technologies, including AI-driven monitoring and digital twin systems, is revolutionising real-time process control and predictive maintenance in metal cutting applications.