Surface Engineering Practices for Extending Tool Life in Nigerian Machine Shops: A Professional Benchmarking Study

This study benchmarks surface engineering practices for cutting tool life extension in medium-sized machine shops in Nigeria, focusing on the adoption and effectiveness of tool coatings, reconditioning, and surface treatment methods. Tool life management directly affects machining productivity and cost competitiveness in Nigeria's growing precision engineering and contract manufacturing sector, yet a systematic assessment of surface engineering practice at the shop level has not been conducted. The study employs a professional survey methodology administered to production engineers and tool room managers at thirty machine shops in Aba (Abia State), Nnewi (Anambra State), and Kano (Kano State). The survey assesses tool material categories in use, the adoption of PVD and CVD coated carbide tooling versus uncoated carbide and HSS, reconditioning practices, and documented tool life measurement. Comparative analysis of tool life data from ten shops using predominantly coated versus uncoated tooling is performed. Findings reveal that coated carbide tool users in the sample achieve average tool lives 2.8 times longer than uncoated carbide users on equivalent machining operations, yet adoption of coated tooling remains below 40 percent in the small shop category due to higher initial procurement costs. Reconditioning capability is absent in 80 percent of surveyed shops. The study recommends the development of shared tool coating and reconditioning facilities through industrial cluster arrangements in Aba and Nnewi. Keywords: surface engineering, tool life, machine shop, Nigeria, cutting tool coating.