Owner: Carbide Inserts URL:carbideinserts.blogspot.com Join Date: Sun, 24 Feb 2008 18:35:07 -0600 Rating:0 Site Description: Rants and Raves regarding carbide inserts, cbn inserts, ceramic inserts, cermet inserts, and inserts in general. Occassionaly will take about nothing, and sometimes other cutting tools. Most of all a resource for information on cutting tools. Site statistics:Click here
Carbide Insert Identification Chart 2008-03-08 20:00:51 Carbide insert identification chart is now available at www.pgstools.com. This chart is helpful for identifying inserts without a home.The insert identification chart is located here:Carbide Insert ANSI Designation Read more:Carbide
, Identification
, Chart
PCD Insert Machining Dont's #1 2008-03-08 19:57:41 PCD is not recommended for the machining of Iron, Cobalt, or Nickel alloys. In the presence of these metals and the heat and pressure created by cutting, diamond is encouraged to revert to the metastable carbon form: graphite. It is possible to machine some stainless steels and other highly alloyed materials, which have the iron, cobalt or nickel tied up in a non-reactive state. Even so, these materials should be machined at low cutting speeds with coolant to reduce any heat generated.
Machining Engine Gear Example 2008-03-08 19:55:27 Welcome to a new section of carbideinserts.blogspot.com. Our focus with these blog posts will be to provide application examples with insert type, speeds and feeds, to hopefully give you a baseline and to help you with your own machining applications. We will add these machining tips on a regular basis, so check back often!Component Description: Engine
GearMaterial: Low Carbon (0.2% C) Cr-Mo Alloy SteelCutting Paremeters: SFM=984 Feed=.010ipr DOC=.051"Wet cutting. Face & External Turning, continuous cut.Recommended insert: CNMG 432ML TT5100 Read more:Example
Machining Cemented Carbide 2008-03-03 11:19:39 This blog entry focus is on machining the following:Cemented carbide with a Co content of less than 17%:1. First choice for machining is CBN2. Should use a round cbn insert 3. The insert should have a chamfered cutting edge4. Machining with coolant is recommended5. Chamfer the workpiece at entry and exit point.Should you require further assistance in choosing an insert or pricing. Please contact the experts at David Richards Engineering. Read more:Carbide
Using PCD and its APPLICATIONS 2008-03-02 17:18:34 Machining Non Ferrous Metals and Alloys including Metal Matrix Composites. Machining Plastics, Rubber, Fibre, Reinforced Plastics and CompositeS Machining Chipboard, MDF and Natural Woods Wear Pads, Gauging Points and Probes PCD can offer dramatic improvements in both efficiency and product quality, but the following points should be considered:- If conventional tools fail prematurely due to breakage, DR-PCD tools are unlikely to fair any better. If excessive vibration, inclusions in component material, or similar problems cannot be avoided, then it may be preferable to continue breaking relatively cheap conventional tools.Howev
Anatomy of a Diamond Coated Insert 2008-03-02 17:16:11 The base material, or substrate, for most thin-film coated-diamond inserts is tungsten carbide (grade C-2). It's basically the same substrate material used for many carbide inserts coated with titanium nitride or titanium carbide. A carbide insert is made from two main ingredients, carbide and cobalt, which are mixed together in various ratios and sintered. Carbide manufacturers guard their ratios and sintering process details the way chefs protect their recipes. The carbide used in an insert is granular, although individual grains are very smallmany formulas call for grains in the single-digit micron range. By using different grain sizes specific cutting performance can be selected. For diamond coatings to adhere more firmly to the substrate, a larger grain carbide is usually specified so
Disadvantages of Diamond Coated Inserts 2008-03-02 17:15:37 Probably the main weakness of thin-film diamond-coated inserts is lack of toughness. CVD diamond films are brittle when deposited on low cobalt substrates. These inserts are not always robust enough to endure high mechanical shock. They are not always the best choice for heavy metal removal and interrupted cutting. As with most coated inserts, thin-film diamond-coated inserts are "throwaways." They cannot be reground. Predicting the performance of CVD diamond inserts is still somewhat uncertain. Vagaries in cobalt distribution in the tungsten carbide substrate makes wear difficult to predict. Nevertheless, compared to non-diamond inserts, a tool-life increase of 10 to 50 times is common--depending, of course, on machining conditions and material. At this time, diamond tools are limited
Carbide Inserts by Style 2008-03-02 17:12:47 An answer to a recent email question I received, here are some of the most common style carbide inserts:CNMG carbide insertCNGA ceramic insertDNMG carbide insertDNGA ceramic insertTPG carbide insertTPG ceramic insertVNMG carbide insertVNGA ceramic insertThese links will take you to tools by Taegutec, Korloy, Kennametal, and generic carbide inserts. Read more:Carbide
, Style
Purpose and Use of the Cut-Off Tool and Holder 2008-03-02 16:59:56 After completing a part in the lathe it is frequently necessary to separate the part from the excess material used for chucking. This operation is best accomplished with the use of a cut-off tool or "parting tool" as it is sometimes called. The Cut-off Tool and Holder
consists of a very slender high speed tool steel cutting blade mounted in a special tool holder. The thinness of the blade (.040") enables it to feed into the part quite easily and at the same time minimizes the amount of waste material. The turning speed for parting should be approximately one half the normal turning speed for any given material. One word of caution; never use a parting tool on a part mounted between centers. The part may bind on the cutter and result in a scrapped part or a broken cutting tool. Parting off Read more:Purpose
Hardturning with CBN - Finish Machining 2008-02-24 18:07:51 Through hardened En31 Bearing Steel MachiningFor finish-machining of hardened steels and certain softer ferrous materials:Surface and through hardened steels High speed steels Bearing steels Hot - work die steels Cold - work tool steels Grey and chilled cast iron Sintered Irons CBN cutting tools machine hardened steels with apparent ease because, using relatively high surface speeds, heat is generated at the point of cutting so the PCBN tool cuts locally softened material. The heat is carried away by the swarf, which becomes brittle and harmless, and the PCBN tool, wh Read more:Finish
Turning Carbon Fiber Composites 2008-02-21 11:58:51 What's the best insert for turning carbon fiber composites?At first it might seem that machining fiber-filled composites with hard cutting tools would be a recipe for disaster. Developers of cutting methods and tools for composites face all kinds of problems. A composite's fiber layers can delaminate from the machined surface; the fibers or other hard reinforcements are abrasive and reduce tool life considerably; and the combination of hard and soft materials that make up a composite complicates the best choice of tool and machining parameters.What do I use then?Diamond will interact with carbon in ferrous materials, so its use is largely restricted to nonferrous workpieces. Today, the automotive industry is the major user of diamond tools in machining components made of aluminum-silicon a Read more:Carbon
, Fiber
What is Cermet? 2008-02-20 11:26:54 What are cermet inserts?Of uniform structure and composition, Cermet is composed of solid titanium carbide (TiC) and titanium nitride (TiN) with a super-alloy metal binder. Cermet has a low friction coefficient which eliminates built up edge and improves surface finish. Its high resistance to thermal deformation and its low conductivity make higher cutting speeds possible and result in lower flank wear and edge cratering. Its high degree of hardness and toughness, with resistance to oxidation, extend tool life.
Inserts for difficult materials 2008-02-20 09:02:51 Superalloys are hard; some grades of titanium are machined at 330 Brinell hardness. With conventional alloys, cutting zone temperatures greater than 2,000[degrees]F soften molecular bonds and create a flow zone for chips. In contrast, the heat resistance that makes HRSAs so desirable keeps them hard throughout the machining cycle.HRSAs also tend to work-harden as they are cut, notching cutting inserts to premature failure. The difficulty cutting HRSAs is compounded where unpeeled stock is covered with abrasive, knife-edged scale that wears cutting edges down even more quickly.Given their machining difficulty, superalloys are cut slowly. For example, Inconel 718 is milled for brake keys with Sandvik GC2040 grade carbide inserts at 200 sfm. Turning speed for the same alloy with Sandvik 7020
Technical Tips for Drills 2008-02-19 16:00:12 Here are links for technical information on drills.The links cover the following:Speeds and Feeds for DrillingSpeeds and Feeds for Deep Hole DrillingFeed Rate per Revolution for drillsTroubleshooting drillsFor more information please visit www.toolinghouse.com for drills, taps, and carbide endmills Read more:Technical
CBN Cutting Tools for Grooving 2008-02-19 10:14:52 Hard part grooving can be a difficult process without the correct tools. CBN cutting tools for grooving can ease that process. During heat treatment, many features of machined components suffer distortion. If the position or dimensions of a groove are critical to the performance of a hardened component, David Richards can offer a simple solution to this problem - ‘Hard Grooving’. Based on the Top Notch system, David Richards supply grooving tools in a wide range of sizes from 0.5 mm width upwards. David Richards supply tools for circlip and ‘O’ring grooves with controlled corners or full radii, either full form for plunging or undersize for profiling.Using such surface speeds typical for turning, grooves are machined at low feed rates (0.01 / 0.05 mm/rev). The low feed rate ensur Read more:Cutting
, Tools
New Products 2008-02-19 10:07:19 PGSTools.com is proud to announce the addition of the following products:Iscar carbide milling insertsandValenite carbide insertsMost tools are in stock and ship same day out of Michigan.Be sure to check out Valenites new inserts for stainless steelVP8515 and VP8525VP8515 is for finishing operations, while the VP8525 is for semi-finishing/roughing operations. Read more:Products
No title 2008-02-06 18:12:03 There is a lot of snow outside
Types of End Mills 2008-02-05 15:39:47 Flutes - Spiral cutting edge on the end mill. 2 and 4 flute end mills are the most commonly used. 2-Flute - Allows maximum space for chip ejection. Used for general milling operations. 3-Flute - Excellent for slotting. Used for general milling operations. 4, 5, 6, and 8 Flute - A greater number of flutes reduces chip load and can improve surface finish, if feed rate remains the same. Ball End - Used to mill die cavities and fillets, round bottom holes and slots. Carbide End Mills
- This tool material combines increased stiffness with the ability to operate at higher SFPM. Carbide tools are best suited for shops operating newer milling machines or machines with minimal spindle wear. Rigidity is critical when using carbide tools. Carbide End Mills may require a
Machining Soft Steels with CBN Inserts 2008-02-04 11:47:55 Finding it difficult to machine soft steels with cbn inserts? I would suppose that soft steel is relative, so generally speaking, cbn inserts will machine steels from 45-65 HRc. For soft steels (the ones on the lower end of the 45-65 HRc), the lower you are on the hardness scale, the faster you will want to machine the material. CBN needs heat to cut at its fullest potential. A quick lesson: CBN generates heat in the shear zone, thus locally anealling the material, cutting it as if it were soft. If you are having trouble with turning using CBN inserts or PCD inserts, please call to discuss your application with David Richards Engineering or email to sales@drengus.com
Where to use ceramic inserts and silicon nitride inserts 2008-02-01 10:31:06 All Irons... use silicon nitride in all applications...turning, boring, milling & facing. Use for roughing, semi-roughing, semi-finishing & finishing applications. Generally speaking, silicon nitrides can be used in all iron applications. All Irons... use the black (CC-20) and/or white (CC-10) ceramic on semi-finishing & finishing applications. They are less costly and harder than silicon nitride (more abrasion resistant & longer lasting). Steels below Rc58 in hardness... use the black (CC-20) and/or white (CC-10) ceramic in almost every semi-finishing & finishing applications. They can even cut with mild interruptions. If your customer isn't using CC-10 & CC-20 on almost every finishing application, he's losing money. Steels above Rc58 in hardness... us
Carbide Insert for Turning Wood 2008-02-01 05:47:34 We have found that this insert performs quite well for turning wood. There are two choices available for chipbreakers. In the first picture is the "TA" and the "HA" is in the second picture. Each one serves a different purpose, so read carefully. Both inserts are from Korloy. These inserts are available in packs of 2. For pricing on carbide inserts for turning wood: www.pgstools.com Read more:Carbide
Machining M2 - Speeds and Feeds - Boring Tip 2008-01-31 11:15:00 Recently came across an application machining M2 with CBN Inserts. Thought it was worth sharing. Here is the breakdown:Job: Finish Bore M2Material: M2Hardness: 58-62 HRcInsert: CDCD51 CBN Insert - Circle $150/eaDepth of Cut: .002" per sideFeed: .005" per revolutionSurface Feet per Minute: 400 SFMThe Problem: Inconsistent tool life and insert would chip after two partsSolution:I am sure that some may have already figured this out based on the radius size of the insert compared to the feed rate, but for those not in the know, here is the fix:Change to:Insert: CDCD 51 T DR-50 Insert $50/ea.Surface Feet per Minute: 300 SFMFeed Rate: .003" - .004" per revolutionDepth of Cut: Keep the sameResult: Increased tool life by more than 15x to 30 parts per edge and saved over $100 per ins
Wear of CBN in Hard Turning 2008-01-21 11:15:56 Hard turning is a developing technology that offers many potential benefits compared to grinding, which remains the standard finishing process for critical hardened steel surfaces. To increase the implementation of this technology, questions about the ability of this process to produce surfaces that meet surface finish and integrity requirements must be answered. Additionally, the economics of the process must be justified, which requires a better understanding of tool wear patterns and life predictions. An ongoing comparative study of wear rates and tool lives under varying cutting parameters is presented here. To date, the study has consisted of seventeen different machining conditions with four different cutting tool materials. Tool life results agree with previous research in this area
NFL Playoff Football 2008-01-13 20:23:53 Its the start of another playoff season in the NFL and much to my disappointment the Detroit Lions have someone once again found themselves on the outside looking in. As a long time fan of the inept Liedowns, I found myself drinking the Kool Aid this season. At 6 and 2 I was in the Club at Ford Field screaming playoffs just like everyone else. I mean even if the Lions went .500 the rest of the way they were going to make the playoffs, but 1 and 7? Are you kidding me? However, in my heart I knew this was coming. I mean it isn't as if the Lions have ever given me reason to think they would do anything but rip the hearts out of long time Lions fans everywhere. It has gotten so bad that we have this flawed logic, that according to Murphy (Law that is) we can't pass on our season tix, bec Read more:Football
Machining D2 with CBN Inserts 2008-01-11 06:41:32 Interrupted cutting D2 tool steel is very difficult and unpredictable. D2 contains up to 14% Chromium and was designed to be used at 50-56 HRc. If the material is hardened to +60 HRc and not tempered very carefully, Chromium Carbide formation at the grain boundaries makes the material impossible to machine with interrupted cutting.
Cnc Milling: a Versatile Process 2008-03-20 07:36:20 Author: George UreComputer Numerical Control (CNC) Milling is a common type of automated machining process. These machines are specially used for drilling, facing, and turning functions. Their classification is based on the number of axes they have. These axes are labeled as x and y for the two horizontal directions while z is for vertical movement. CNC milling is a cutting process that is used to remove metal or plastic from a block of stock material by the rotating action of the tool. The tool is moved in three (or more) directions to get the desired cut of the material.CNC Milling machines have been programmed with the help of a set of commands called G-codes. These codes are special CNC functions in alphanumeric format.The cutting tool is usually rotated along the axis, which is perpen Read more:Versatile
, Process
Using Coolant - CBN Inserts - Interrupted Cutting 2008-03-29 11:43:24 Although most of the heat essential for efficient cutting exits with the chip, any increase in the temperature of the component will make accurate measuring difficult. Coolant can be used to reduce this effect.Coolant can be used to drive away any swarf which might interfere with the cutting edge, particularly in boring operations. Coolant can help reduce vibration, especially where rigidity is limited.Where interrupted cutting with CBN inserts occurs, coolant should not be used as this will thermally shock the CBN tool as it comes out of the cut, resulting in premature failure. Although interrupted cutting with coolant will never improve tool life, it is possible to use coolant machining hardened steel with DR-450 CBN inserts and coolant can be used when machin Read more:Cutting
Machining Rolling Mill Roll with CBN 2008-03-31 06:32:31 White Iron Roll MachiningApplication Example:Component: Rolling
Mill Roll (1 metre diameter x 3 metre long) MachineTool: Craven Centre Lathe Material: Chilled Cast Iron ( 55 Hrc) Operation: Turning Depth of Cut: 2 mm (0.08") Insert: RNMN 120300T DR-100 Surface Speed: 100 m/min (330 ft/min) cutting without coolant Feed Rate: 0.2 mm/rev (0.008"/rev) Surface Finish: N/A Tool Life: Average 40 minutes contact Comments: Semi-finishing for grinder � machine n
Benefits of Carbide Cutting Tools 2008-04-04 14:51:08 Carbide Cutting
Tool in ActionBenefits
of Carbide Cutting Tools
Author: John MorrisIn every machining system, one simply can't ignore the important role that cutting tools play. Oftentimes, the quality of a finished product would rely on the quality of the cutting tools. The quality and the performance of cutting tools would also directly affect a machining system's overall productivity. It is because of their importance that manufacturers would take into consideration several criteria before eventually buying a piece of cutting tool for their machining system. Included in these criteria are the tools ability to last long under rigorous operating conditions and their capability to perform at very high speeds. Also important is the tool's resistance to wear and tear, including resistance to Read more:Carbide
PCD Insert Tooling for Plastics 2008-04-02 14:45:54 Plastics and reinforced plastics can be machined with PCD Inserts and PCD tooling. The general perception is that plastic materials are easy to machine. However, soft plastics are not always so stable, and the machining process, which always generates heat, can affect dimensional and material properties like surface texture and colour, if the correct cutting tool is not applied.PCD tools are particulary effective on abrasive plastics where plastics are reinforced with carbon fibres (CF) or glass fibres (GF). For more information on machining plastics with PCD insert or PCD tooling please contact the experts at: David Richards Engineering Limited Or David Richards Engineering Corporation Read more:Plastics
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