NASCAR fans have the opportunity to not only get up close and personal with two high-powered stock cars at machine tool builder Doosan Infracore’s Booth S-8100, but also meet their drivers. Brian Scott will appear alongside his No. 11 Toyota Camry—which sports Doosan’s logo—at 1 p.m. Wednesday, Cemented Carbide Inserts and Kyle Busch will show off his No. 18 M&Ms Camry at 11 a.m. Thursday. Both drivers are members of Joe Gibbs Racing (JGR), which has partnered with Doosan for 15 years and currently uses 23 of the company’s machines at its shop in Huntersville, North Carolina.
Surrounding the flashy racecars, however, are a number of purposefully more down-to-earth displays designed to appeal to the real reason folks attend IMTS—to explore technology that can help boost the bottom line. Whereas displays in other booths might showcase machines cutting fanciful, artistic components designed especially for demonstration purposes, all Doosan machines under power are cutting actual parts from actual customers, says John Ross, marketing manager. “As opposed to parts that have no place in the real world, we wanted to showcase applications that people walking through the booth can relate to,” he explains. Examples include turning of a large oil industry pipe, an application performed at Houston-based oilfield company Baker Hughes, and machining of a die for a firearm stock manufactured by Remington.
Finally, tungsten carbide inserts Mr. Ross says he believes booth visitors will take particular notice of one product: the DooCell. Demonstrated for the first time at IMTS, this cellular manufacturing system uses a touchscreen controller and diagnostic system designed to take automation beyond simply pairing a robot arm with a turning cell or machining center. According to the company, its simple design and operating features enable users to assess performance and diagnose problems without day-to-day use of complex robot pendants.
The Carbide Inserts Website: https://www.estoolcarbide.com/product/cemented-carbide-inserts-pvd-coating-snmg120404-ha-use-for-planer-tool/
Jason Blake (left) is president of JKB Tool and Walter Oko is vice president of operations. The shop began its orthopedic part business 6 years ago. Now it keeps 12 Swiss-type turning centers busy full time.
Irma Hernandez inspects each bone screw for visual and dimensional characteristics. Careful inspection, documentation and tracking are requirements of JKB’s customers and the FDA.
Jason Blake (left) is president of JKB Tool and Walter Oko is vice president of operations. The shop began its orthopedic part business 6 years ago. Now it keeps 12 Swiss-type turning centers busy full time.
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In the film “The Graduate,” a neighbor gave one hushed word of business advice to Dustin Hoffman’s character: “plastics.” That screenplay was written more than 30 years ago. If it were written 15 years later, that word might have been “medical.” The exploding growth in the market for medical components, such as metal joints, bone screws and laparoscopic tools, has helped many job shops survive when orders from other industries lessened or disappeared in the late 1990s. The medical market is expected to continue to be strong as life expectancy lengthens, the Baby Boom generation crosses into senior citizenship, and orthopedic and microinvasive surgical advancements continue to evolve.
Before a shop seeks out medical customers, there are factors to consider to help ensure the shop’s success in the medical market. These have to do with the nature of orthopedic parts, the optimum way to produce them efficiently, quality requirements by both medical companies and the government, along with labeling and packaging.
JKB Tool in Milford, Connecticut, is a company that made a leap to medical machining about 6 years ago. The shop made its reputation in the 1980s as a designer and builder of sophisticated automatic assembly and test systems. An adjunct to that business was a small contract production shop and, later, a stamping business. Jason Blake, son of the founder, has worked with his dad since the business started, deburring parts in the family’s basement.
“When I graduated from college, I came to work at JKB full time,” Mr. Blake says. “That was 1994, and by 1997, the automation projects were getting bigger and more complex, but were less profitable. We were making money in the stamping business, but more jobs were going to China and Mexico, so the future in that was questionable.” As Mr. Blake tells it, the company was on the verge of despair by 1998.
“We had one hopeful spark going for us,” he says. “We had a small machining contract for a laparoscopic tube running on our CNC milling machine. We saw a future in medical parts and made a commitment to do whatever was necessary to go after more of that business; we had to become more efficient if we wanted to be successful at it.”
Mr. Blake was particularly interested in the orthopedic segment and understood that the shop would have to invest in new multifunction equipment to be competitive. In a typical bone screw, for example, the operations are thread whirling, broaching, gundrilling and micro-milling. If conventional equipment is used for each operation, then three or four machines would be required.
“I went to the EASTEC trade show in ’98 and looked at CNC screw machines for the bone screw parts that we wanted to attract, plus additional laparoscopic parts,” Mr. Blake says. “I knew that these were multifunction machines, but that’s all I knew. I had never worked on one, nor had any of our employees.”
JKB purchased a “Deco” Swiss-type sliding headstock turning center from Tornos Technologies (Brookfield, Connecticut) in 1999. The machine was 60 percent faster (41 seconds) in a competitive test involving the laparoscopic tube part. Today, 6 years later, Mr. Blake and his crew produce that part even faster (36 seconds) as a result of gaining expertise in the technology.
First Machine Once the machine was on the floor, the shop employees began working to master bone screw manufacturing. Titanium bone screws are used for spinal corrective surgery, trauma, and other types of bone repair and correction. Other bone screws are made of 316 stainless steel. They are produced by the millions in the United States to strict demands for tolerance, surface properties, cleanliness and packaging. The titanium screws range in length from 6 mm to 80 mm and have ODs from 2 mm to 8.5 mm. They typically require a 0.4-micron to 0.8-micron surface finish and dimensional tolerance of ±0.025 mm. Customer specifications also often include the addition of an anodized coating for color coding different sizes and types of screws. Surface finishes and tolerances must take into account the coated layer, allowing for additions or reductions in material.
“It was a difficult time,” Mr. Blake says. “Remember, this was a new discipline for us, using a new technology in a new market. This was our very first screw machine.”
It was a challenge for JKB to adapt to the large volume of parts coming off the machine.
“If we made a mistake in programming or setup or tooling, it set us back in production time,” Mr. Blake says. “The bone screw machining process is not very forgiving.”
Mr. Blake and his staff also had never worked with titanium, which is a tough, flammable material. If a tool breaks, the material’s temperature is so high that it can ignite the cutting fluid. It’s necessary to have fire extinguishers at every machine. According to Mr. Blake, he and his employees worked 14-hour days, 7 days a week for about 4 months to learn how to make the parts.
“But we were driven. We were hungry. We persevered,” he says. “The only thing we didn’t worry about during that learning phase was threading, which is usually the big problem for people requiring expensive, dedicated equipment. The Deco has a thread whirling attachment that puts the thread on so easily. They come out burr-free; we can put any shape we want into it; and we get tremendous life out of the tooling inserts.”
First Contract JKB won a bone screw contract in 2000. The company sold off its press equipment and bought another Deco.
“We got the business because we could produce it for less than our competitors and with better quality and faster delivery,” says Mr. Blake.
Armed with confidence and experience in the technology, and driven by the spirit of survival and perhaps also by youth (Mr. Blake is 34; most of his employees are younger), the orthopedic part business grew.
“There were bumps and challenges along the way, of course,” he says. “One part comes to mind—a fixed-angle bone screw. We worked on that part for 2 years to make it successfully. We use all 20 tool positions on the Deco to make this part complete in one setup. The elliptical shape of the head posed unique challenges, such as part holding and the many operations that have to be performed in the machine’s counter spindle. The Deco gives you eight tool positions for counter operations, all of which can be live tools.”
JKB’s goal is to always make a part in what it calls “done-done” in the machine. The shop always tries to avoid secondary operations.
Art Deco The ten-axis Deco machine can use two turning tools at the same time, completing rough and finish cuts in the same operation. One of the machine’s cross slides accepts up to four live tools for operations such as cross milling and off-center drilling. A gundrilling and high-pressure coolant attachment can be mounted on the end-working unit. This feature is a plus when producing cannulated bone screws, which are screws with a 1.5-mm to 2.5-mm hole through the entire length. JKB prefers to gundrill the hole rather than to buy cannulated stock, which is often unavailable. Polygon milling of flats or contours can be accomplished using the machine’s optional C axis on the main spindle.
While the bar in the main spindle is machined, operations are performed on the previously parted piece mounted on the counter spindle. For example, the counter spindle can present the part’s cut-off end to as many as four live tools or turning tools. In effect, the user gets these operations at zero time because they occur while the part in the main spindle is machined. Users such as JKB can minimize part cycle times by balancing operations between the main and counter spindles. As many as ten axes can be controlled simultaneously on the Deco, and up to four tools can be operating simultaneously.
“The programming is a different approach,” Mr. Blake says. “Tornos calls it PNC, parallel numerical control, because so much is happening simultaneously, but it’s the control and dedicated software that give you the productivity. The machine goes from operation to operation before you finish an eye blink. The payoff is worth learning it.”
The machine’s software automatically calculates real machining times, taking into account tool paths, operation sequences and other cutting data entered by the user. It also incorporates canned cycles that speed programming, such as barstock advance, cut-off and pick-up by the counter spindle. It also displays the part’s production rate.
Quality Control There are other aspects to consider when getting into the medical business besides efficient and advanced manufacturing technology. Not only must a shop be certified to ISO 9001/14001 for most medical OEMs, but there is also a myriad of U.S. Food and Drug Administration requirements involving inspection, reporting, labeling and packaging.
“It was an overwhelming prospect when we first got into the medical market; however, we plowed our way through to do all the right things for our new customers,” says Mr. Blake. “We invested heavily in inspection equipment, because each and every part we make must be viewed under a microscope for physical characteristics, such as marks on the bone thread or any burrs on the part. We also check dimensional accuracy. We achieved our ISO 9001/2000 certification and are registered with the FDA. The regulations are somewhat of a moving target at times, but if a shop wants to be in this business, which we do, you do whatever it takes to be successful.
“Our next goal is to run a paperless shop and documentation system. Our customers and the FDA require very accurate record keeping called Device History Records, which are often kept for up to 30 years.” Labeling and packaging is another area with particular requirements in the medical industry. Each part or assembly must be individually marked with vendor code and lot code. WNMG Insert JKB uses a quality-approved vendor to laser etch each part and also anodize the parts if required by the customer. When the parts return to JKB, they are packaged and shipped per customer specifications.
“If we are shipping more than one lot, they are segregated by lot,” says Mr. Blake. “The most important thing is accurate documentation. It’s everything in the medical business.”
Putting It All Together “Generally speaking, the main difference between the medical industry and the others we have been in is that we have to be more careful, more precise,” Mr. Blake says. “All aspects have to be as close to perfect as humanly and technologically possible—the parts, the inspection, the documentation—but if a shop is as motivated as we were, it’s rewarding. We’re in the black. The work is interesting and challenging. tungsten carbide inserts And we like the idea of making products to improve a person’s quality of life.”
Mr. Blake is a strong believer in reinvesting. He says he invests 80 percent of the profits back into the business. The company now has 12 Decos on the shop floor, and will order four more this year. He says the company buys the most expensive tooling, and it has switched to a vegetable-based oil that is double the cost of conventional oils. According to Jason, his tool life savings makes up the difference. He has also developed his staff and takes a sports team management approach.
“I see myself as a coach who has 55 talented players, and I do whatever I can to keep them happy and performing at peak levels,” he says. “I pay them well and we all work very hard because we want to win. Many of them were with me when the business was struggling. They don’t want to go back there. Neither do I. We do whatever it takes to maintain our competitive edge. We’re always in R& D mode, you might say, always trying new things to grow and keep that edge razor sharp. If we don’t, someone else will.”
About the author: Lynn Gorman is a communications and marketing specialist in Bethlehem, Connecticut. Tornos Technologies U.S. Corp. is one of her clients.
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Cemented tungsten carbide is one of the few materials that has had a bigger influence on both our economy and our culture as a result of industrialization. This material is utilized in the production of a wide variety of items due to its high hardness and resistance to wear. Some of these products include ballpoint pen balls, fishing rod guide rings, wear parts, dental drill bits, armor-piercing shell cores, and most importantly, cutting tools.
In point of fact, coated aluminium carbides are the cutting tools that see the greatest volume of use on the market. They do, after all, bring great levels of efficiency to the production process, which, in turn, makes many of the items that are used on a daily basis more inexpensive.
Nevertheless, because there is such a wide variety of modern coating methods and coating materials, it is not always simple to establish which carbide inserts for aluminium are the best for a particular application.
Tips When Milling Aluminum
Aluminum is more technologically sophisticated now than they were twenty years ago. They are less heavy, have greater tensile strength, and are more reasonably priced. Carbide Threading Inserts In point of fact, when you’re under continual pressure to decrease expenses, aluminum might be a good option to steel to use. However, there are a number of factors to consider and obstacles to overcome when attempting to select the appropriate tools for your aluminum milling processes.
To begin, it is essential to have a solid understanding of the many kinds of aluminum and to be aware of the fact that each kind possesses a unique degree of strength as well as a unique level of cost and machinability. And that in addition to these categories, there are also various grades, each of which has a unique combination of mechanical characteristics.
You also need to take into account the complicated nature of aluminum’s metallurgy. The casting process results in the generation of microstructures that have varying qualities on the surface and within the tungsten carbide inserts interior body of a component. The grade of aluminum also differs considerably from one foundry to the next.
CNC routers are commonly utilized with wood and acrylics, but they’re also capable of dealing with materials like aluminum. Adapting the method to meet the varied features of aluminum is the key to successful aluminum milling.
Use these hints to overcome challenges and make high-quality parts.
Calculate The Correct Feed Rates and Speeds
Aluminum, like other metals, has a narrower range of ideal feeds and speeds than wood or acrylics. Cutting aluminum necessitates a greater spindle speed, which may push your CNC mill to its limitations.
Feed rates that are excessively sluggish might create friction, which shortens the tool’s lifespan. Overburdening the machine with overly fast feed rates can cause it to break. The previous method of “learning by ear” leaves far too much space for error. You can use a feeds and speeds calculator to calculate more precise rates.
Use Smaller Diameter Carbide-Coated Bits
High-speed steel and cobalt are unlikely to be up to the task of cutting aluminum due to the higher RPMs involved. Carbide is a harder material that makes it a better choice for bits. Smaller diameter bits are required for faster milling speeds. Another advantage of carbide is that it is stiff, which protects against tool deflection.
Maintaining a Consistent Temperature
Aluminum is more susceptible to temperature changes, resulting in waste as finished parts are out of spec. Use gear and software that can keep temperatures within safe limits.
Clear Chips Thoroughly
Aluminum chips have a “stickiness” feature that leads them to become “welded” to the tool, resulting in poor quality work and excessive machine wear and tear. You shouldn’t rely solely on dust collectors. Check the machine frequently to ensure that all chips have been removed. To prevent chips from sticking, spray the machine with a coolant mist or another lubrication.
Take It Slow and Steady
Making deeper cuts to save time may be tempting, but this method might backfire by making it more difficult to clean chips. Stick to frequent shallow passes for better control and access to the chip removal area.
Lower the Number of Flutes
By forcing the chips to be packed in too tightly, too many flutes can exacerbate the chip problem. When milling aluminum, use a maximum of three flutes. Larger chips have an easier time escaping when there is more space between the cutting blades.
Our revolutionary stacked aluminum milling technology eliminates the time-consuming procedure of stacking, drilling, and riveting to produce flawlessly finished parts..
Cutting tool firms, notably HUANA, are always creating innovative turning and milling solutions to assist overcome the variations and problems of dealing with aluminum materials. But this may be an achievement in itself because every material, manufacturer and application throughout the world is unique.
However, here are some crucial recommendations you should constantly bear in mind:
Why Have your workpiece qualities under the best possible control since deviations might negatively affect total production, either directly or indirectly. When the qualities of the workpiece are unknown, you may look to tooling systems and cutting procedures to help compensate for any deficiencies in the quality of the material. The challenge, on the other hand, is in determining which carbide insert for aluminum and tools are suitable for your particular application.
When it comes to turning aluminum, everything relies on the particular application you’re using it for. You need to figure out how many different processes are involved in order to achieve your objectives. If the qualities of your workpiece are uncertain, you could decide to incorporate an additional finishing cut, using carbide insert for aluminum which will not cause delays in the production schedule. You may, however, cut down on the number of processes by ensuring that the equipment you use is appropriate for the environment and the specifications of the component.
When compared to turning the material, milling aluminum involves a significant increase in the level of complexity involved in the process. It is crucial to consider the whole cutting solution; however, the type of carbide inserts for aluminium that you employ is only one component of that solution. You need to take into consideration, in relation to your component, the kind of cutter body as well as the number of cutting edges. This is in addition to the carbide insert for aluminum geometries and grades. In addition, heat and coolant should be avoided as much as possible while milling aluminum.
There is no genuine “one size fits all” answer to the question of how to choose the appropriate sort of carbide inserts for aluminium to use when milling aluminum. There are several different factors to consider. But in general, the kind of milling cutter that seems to be making a lot of headway these days would be a negative cutter with carbide inserts for aluminium that have positive rake angles and in a grade that can handle both wet and dry conditions. This would be the type of milling cutter that a negative cutter with carbide inserts for aluminium that seems to be making a lot of headway these days.
You need to give some thought to whether or not your machine tool has carbide inserts for aluminium. Aluminum materials present a higher dynamic load during the milling process, which means that your machine tool needs to be extremely robust in addition to providing high power and high stability. This places strain on the machine as a result of all of these requirements. In these particular circumstances, however, a negative cutter that has a positive rake angle can assist in lowering the power needs of the machine tool and reducing the stresses that are placed on machine spindles as well.
Milling aluminum requires the use of carbide inserts for aluminium, which are employed in the shaping process. In order to acquire the proper form for suitable materials, it will be essential to make use of carbide inserts for aluminium that are of the appropriate quality and shape. When it comes to aluminum milling, HUANA offers a wide variety of forms, sizes, and quality for turning and boring.
Which Groove Suits For Aluminum?
Our extensive collection of light, medium, and heavy duty Groove Aluminum wheels provides options that are suitable for a wide variety of applications and industries.
How to buy Groove that suit for aluminum?
The process of choosing the right Aluminum groove that best meets your requirements may be broken down into the following easy phases.
First, Determine The Diameter Of The Wheel
If you are replacing an existing Aluminum wheel, this should be a reasonably smooth process for you; but, if you are ordering for a new application, you should consider how you want to mount it to your apparatus as well as the weight that it needs to hold before placing your purchase.
Second Step, Select the Appropriate Aluminum Groove Material
When it comes to your castors and wheels, this is potentially a very crucial factor to take into account.
Will the castor be utilized in an outdoor setting?
Will the wheels come into touch with any substances that might be dangerous or corrosive?
Will the wheels be capable of supporting excessive weights, such as up to one ton?
Third Step, Check the Load Capacity
You need to be aware of the load capacity of your castor wheels in order to prevent them from collapsing under excessive weights. However, you do not want to over-specify the castor wheels (for example, ordering those with a capacity of 500 kilograms when you only need those with a capacity of 200 kilograms), as the cost of the castor wheels will typically increase in proportion to the weight of the load.
How do you determine the load capacity?
Take into consideration how heavy the tool is.
The utmost weight that can be supported by it
First, add all of them together to determine the overall weight or burden, and then divide the amount by three.
The final number will represent the maximum weight that each castor should be able to support.
Inserts For Aluminum Model and Size
When working with turning applications, it is vital to use the correct form of an insert, and this shape is decided by the suitable point angle in order to maximize both strength and economy. The needs of the application and the amount of room available in the application for the cutting tool will determine the appropriate size of the carbide inserts to use when working with aluminium. Large insert sizes necessitate more stability when working with robust machinery; the usual size of carbide inserts for aluminium often climbs up to 25 millimeters. After the project is finished, the height of rotation may frequently cause a reduction in the scale of the insert.
How Do You Determine the Appropriate Size for Carbide Inserts Aluminum?
Eliminate the most important amount of the cut depth.
Find the needed cutting length, also known as LE, taking into account the tool holder entrance angle, the cutting depth, and the machine specification.
Check that the right slice length for the insert is known to you.
Creating a Turning Insert Form
Huana provides you with an easy-to-use chart that will assist you in selecting the appropriate insert form for any project. The design of the insert also has a significant impact on how deeply or at what angle it cuts into the metal. In order to select the suitable turning insert form for your project, you will first need to determine whether it is a rough, completed, or general turning task. When you have an understanding of the overall scope of the task at hand, the next step is to determine the tools that are necessary for the work by conducting some preliminary study to verify that you are employing the appropriate tools.
Contact HUANA For Buying Best Carbide Inserts For Aluminum
But in the end, because there are so many factors to think about, if you want to boost the productivity and predictability of your aluminum milling operations, the best course of action for you is to work closely with the cutting tool provider. This is the best way to achieve your goals. You may get the very best carbide inserts for aluminium in a variety of forms and sizes by getting in touch with HUANA.
Contents hide 1from raw material to final product 2Beginning in the ground 3Grain size defines properties 4Mix it up 5Sintering 6coatings drop the scene 6.1Chemical vapor deposition 6.2Physical vapor depositionfrom raw material to final product
Tungsten carbide, commonly referred to as “carbide”, is a common material in shops. This Tungsten Carbide Inserts tungsten and carbon compound has completely changed the world of metal cutting in the past few decades, increasing speed and feed rate and prolonging tool life. Tungsten carbide was first studied as a tool material in 1925. Later, Ge set up a special department to produce tungsten carbide cutting tools. In the late 1930s, Philip M. McKenna, the founder of Kennametal, found that adding titanium compounds to the mixture could make tools work better at higher speeds. This began to move towards today’s lightning cutting speed.
“Cemented carbide”, the materials constituting tools and blades, are actually tungsten carbide particles along with other materials, which are cemented together with metal cobalt as binder.
Beginning in the ground
There are several tungsten ores that DNMG Insert can be mined, refined into tungsten or made into tungsten carbide. Wolframite is the most famous. The ore is crushed, heated and chemically treated into tungsten oxide.
Then, the fine tungsten oxide is carburized into tungsten carbide. In one method, tungsten oxide is mixed with graphite (carbon). Heating the mixture to 1200 ? C（2200 ? F) Above, a chemical reaction occurs to remove oxygen from the oxide and combine carbon with tungsten to form tungsten carbide.
Grain size defines properties
The size of carbide particles determines the mechanical properties of the final product. The particle size will depend on the size of tungsten oxide particles and the time and temperature of treating the oxide / carbon mixture.
Tungsten carbide particles are a small fraction the size of a grain of sand. They can range in size from half a micron to 10 microns. A series of sieves sort out different particle sizes: less than 1 micron, 1.5 micron, etc.
At this point, tungsten carbide is ready to be mixed into “grade powder”. In the tungsten carbide industry, people speak of grade rather than alloy, but they mean the same.
Tungsten carbide enters a mixing vessel together with other components of this grade. Powdered cobalt metal will act as a “glue” to bond the materials together. Other materials such as titanium carbide, tantalum carbide and niobium carbide are added to improve the properties of the material during cutting. Without these additives, when cutting ferrous materials, tungsten carbide tools may react chemically between the tool and workpiece debris, leaving pits in the tool, especially in high-speed cutting.
Mix it up
All these ingredients are blended with a liquid such as alcohol or hexane and placed in a mixing vessel, often a rotating drum called a ball mill. In addition to the grade ingredients, cemented balls 1/4″ to 5/8″ in diameter are added, to help the process of adhering the cobalt to the carbide grains. A ball mill may be as small as five inches in diameter by five inches long, or as large as a 55-gallon drum.
When the mixing is complete, the liquid must be removed. This typically happens in a spray dryer, which looks like a stainless steel silo. An inert drying gas, nitrogen or argon, is blown from the bottom up. When all the liquid is removed, the remaining dry material is “grade powder,” which looks like sand.
For cutter inserts, the grade powder goes into insert shaped molds specially designed to allow for the shrinkage that will happen later on in the process. The powder is compressed into the molds, in a process similar to how pharmaceutical tablets are formed.
Sintering
The powder compacts are heated to a certain temperature (sintering temperature) and to maintain a certain time, then cool down, to obtain the required properties of materials, this process is called sintering. In the process of sintering, the bonding between particles is realized by heating by means of atomic migration. When the particles are bonded, the strength of the sintered body increases, and in most cases the density increases.
After the inserts are removed from the furnace and cooled, they are dense and hard. After a quality control check, the inserts are usually ground or honed to achieve the correct dimensions and cutting edge. Honing to a radius of 0.001″ is typical, though some parts receive a cutting-edge radius of half a thousandth or as large as 0.002″, and some are left “dead sharp,” as sintered.
Some types and designs of inserts come out of the sintering furnace in their final shape and in-spec, with the correct edge, and don’t need grinding or other operations.
The process for manufacturing blanks for solid carbide tools is very similar. The grade powder is pressed to shape and then sintered. The blank or stock may be ground to size afterward before shipping to the customer, who will form it by grinding or perhaps EDM.
Inserts bound for most non-ferrous applications may be ready to package and ship at this point. Those destined for cutting ferrous metals, high temperature alloys or titanium, will need to be coated.
coatings drop the scene
To prolong tool life under challenging cutting conditions, many types and combinations of coatings have been developed. They can be applied in two ways: by chemical vapor deposition (CVD) or physical vapor deposition (PVD). Both types are applied in furnaces.
Chemical vapor deposition
For CVD, the coating is usually 5-20 microns thick. Milling and drilling blades typically achieve a hardness of 5 – 8 microns because these operations require better surface finish and more impact, so greater edge toughness is required. For turning applications, the coating is often in the range of 8-20 microns. When cornering, heat and wear are often more worrying.
Most CVD coatings consist of multiple layers, usually three layers.
Each company has its own coating “formula”. This is a typical scheme, which consists of three layers.
? a layer of titanium carbide with hardness and wear resistance
? a layer of alumina, which maintains hardness at high temperature and has very stable chemical properties
? a layer of titanium nitride to prevent metal accumulation caused by workpiece fragments welded to the tool. This coating is golden and edge wear is easily observed. In order to apply CVD coating, the parts are placed on pallets and sealed in the furnace. The furnace was evacuated.
Physical vapor depositionPVD coating machine
PVD coating is usually about 2-4 microns thick. Different manufacturers use different layers. These PVD coatings are very suitable for cutting high temperature, nickel based, cobalt based or titanium based materials, and sometimes steel and stainless steel.
Titanium carbonitride, titanium nitride and titanium aluminum nitride are widely used as PVD coatings. The latter is the hardest PVD coating with the highest chemical stability.
The inserts are mounted on the frame so that they are separated from each other. Each rack rotates and the entire rack assembly rotates in the furnace so that each surface of the insert is exposed to the deposition process. The stove was emptied.
A strong negative charge is applied to the plug-in. Install a piece of titanium or titanium and aluminum on the wall or floor of the furnace. Metals evaporate through an arc or electron beam, releasing positively charged metal ions. These ions are attracted by negatively charged inserts. Nitrogen and methane are added appropriately to obtain different types of coatings.
After the insert is removed from the furnace, it can be ground again or packaged and shipped directly.
By continuously improving the design of tungsten carbide tools and developing better and better coating technology, tool manufacturers are coping with the pressure of increasing feed rate and speed, as well as the need to prolong tool life and reduce cost.
Carbide saw tips are used for cutting wood, metal, or other hard material. They can be hand-operated or power-driven. Our saw tips are used in surface processing of cast irons, colored metal, and alloys, as well as nonmetal materials for hard metal, carbide rough turn, rough planning, and precision milling. We provide improved carbide grades for woodworking and customized tooth geometry design on request, but also give advice on what tips are the most suitable for TNMG Insert customers’ use.
Virgin material with fine grain size
Dust-free workshop
Advanced technology and production equipment
All of the mould with precision design
Strict quality testing and inspection
Advantages as following: 1.The advanced computer-controlled HIP furnaces are applied to provide more pressure during the sintering process in order to get denser structure.
2. We carefully select and control the excellent quality of our raw powders. Powder spray drying technology ensures the uniformity of distribution of particles.
3. We offer customers a wide array of processing Tungsten Steel Inserts services on-site including centerless grinding, CNC cylindrical grinding, CNC internal grinding, wire EDM, and laser etching, etc. You can contact us for more information about carbide saw tips.
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