Tag: Non-standard Carbide Insert

As moldmakers continue to utilize different mold materials to optimize the efficiency of the molding process, machineability of those materials and the economics of the metal cutting process will continue to be a dynamic one. Cutting tool non-standard carbide insert manufacturers will continue to develop new grades, coatings and top form geometries to improve wear and tool life of those cutting tools, which is already being found in new micrograin carbide grades (<0.4fm) with PVD TiAlN coatings specifically developed for machining steels pre-hardened over 54 Rc. In addition, there is a trend toward dry cutting processing to increase economic efficiency and meet the expanding ecological requirements. Coatings will play a crucial role here with respect to improving thermal energy management, lubrication, low coefficients of friction and the kind of chip evacuation required for dry cutting applications. For example, a ZrO2 coating is very effective in dry machining due to its high fracture toughness and low friction coefficient.

In most cases, there never will be one cutting tool non-standard carbide insert solution that works for everyone. There are too many variables with respect to different machines, various coolants, speeds and feeds, and machining environments. What this article has attempted to show, in as brief a context as possible here, are basic starting points for non-standard carbide insert selection for the various mold materials. The ultimate selection is left to you, hopefully now possessing a better knowledge.

Non-standard carbide inserts are replaceable and usually indexable bits of cemented carbide used in machining steels, cast iron, high temperature alloys, and nonferrous materials. Non-standard carbide inserts allow faster machining and leave better finishes on metal parts. Non-standard carbide inserts can withstand higher temperatures than high speed steel tools.

Cemented carbides are composed of a metal matrix composite where carbide particles act as the aggregate and a metallic binder serves as the matrix. The process of combining the carbide particles with the binder is referred to as sintering. During this process, the binder eventually will be entering the liquid stage and carbide grains (much higher melting point) remain in the solid stage. The binder is embedding/cementing the carbide grains and thereby creates the metal matrix composite with its distinct material properties. The naturally ductile metal binder serves to offset the characteristic brittle behavior of the carbide ceramic, thus raising its toughness and durability. Such parameters of carbide can be changed significantly within the carbide manufacturer’s sphere of influence, primarily determined by grain size, cobalt content, dotation, and carbon content.

Carbide is more expensive per unit than other typical tool materials, and it is more brittle, making it susceptible to chipping and breaking. To offset these problems, the carbide cutting tip itself is often in the form of a small insert for a larger tipped tool whose shank is made of another material, usually carbon tool steel. This gives the benefit of using carbide at the cutting interface without the high cost and brittleness of making the entire tool out of carbide. Most modern face mills use non-standard carbide inserts, as well as many lathe tools and endmills.

To increase the life of non-standard carbide inserts, they are sometimes coated. Four such coatings are TiN (titanium nitride), TiC (titanium carbide), Ti(C)N (titanium carbide-nitride), and TiAlN (titanium aluminum nitride). Most coatings generally increase a tool’s hardness and/or lubricity. A coating allows the cutting edge of a tool to cleanly pass through the material without having the material gall or stick to it. The coating also helps to decrease the temperature associated with the cutting process and increase the life of the tool. The coating is usually deposited via thermal CVD and, for certain applications, with the mechanical PVD method at lower temperatures.

Non-standard carbide insert are widely used in life. In fact, there are many types of non-standard carbide insert. Below, we will follow the non-standard tool manufacturers to understand the four types of non-standard carbide insert!

1. Non-standard blade: non-standard PCD blade, non-standard CBN blade, non-standard threaded blade, non-standard grooved blade, non-standard car blade, non-standard milling blade;

2, welding: reamer, forming knife, drill bit, thread cutter, etc.;

3, the overall hard alloys: non-standard drills, non-standard step drills, non-standard reamer, non-standard milling cutters, non-standard forming knives, non-standard step reamer, small parts cutters;

4. Discarding cutter bar cutters: non-standard chamfer drills, non-standard violent drills, non-standard step drills, non-standard forming knives, non-standard forming knives, non-standard boring knives, various non-standard milling cutters, various Non-standard milling cutters and so on. In addition, non-standard carbide insert are different from normal carbide insert, and there are certain requirements for materials used for non-standard carbide insert.

Completely replace the mainstream products of Japan and South Korea.

Non-standard carbide inserts are used for face milling for larger parts, profile milling, milling of larger pockets, etc.

The non-standard carbide inserts are extremely versatile and are the first choice for profile milling. They can be used for most milling such as face milling, pocket milling, round bottom milling, and side milling.

Non-standard carbide inserts are the first choice for roughing tools that are efficient and have high metal removal rates.

The non-standard carbide insert tool means a continuously variable lead angle, ranging from 0 to 90 degrees, depending on the depth of cut.

The round insert has a very strong cutting edge and is suitable for high feed rates due to the thin chips that are produced along the long cutting edge.

The thin chipping effect is suitable for processing heat-resistant high-quality alloys and difficult-to-machine materials.

Comprehensive consideration of various factors, a variety of chipbreaker design, a reasonable combination of a variety of ideal coatings, the non-standard carbide insert in the low carbon steel, die steel, high alloy steel, high hardness steel, stainless steel and other materials have excellent performance .

During processing, the change in the direction of the cutting force along the radius of the non-standard carbide insert and the resulting pressure are determined by the actual depth of cut. The development of modern insert geometries has made non-standard carbide insert milling cutters more versatile because of their smooth cutting action, low machine power and low stability requirements.