Cemented Carbide Inserts Wear Features

Cemented carbide inserts as a tool, has the following four important properties:

1) high hardness is not lowered.

2) Long-term use will not wear.

3) By the high pressure will not be deformed or cracked.

4) They can be processed into a very sharp cutting edge shape, nor bending deformation.

However, if the use or uses wrong, even if it has a superior performance cemented carbide inserts will look completely different. Special mention, the cemented carbide inserts cutting speed is very sensitive. cemented carbide inserts made ​​of the same material, if the cutting speed is different, the wear condition of a cutting edge is also different.

Cemented Carbide Drill Processing Abnormal &Solutions

Cemented carbide drill tool is used for drilling in the solid material through holes or blind holes and reaming of the existing holes.

Cemented carbide drill processing abnormal causes and countermeasures

Situation	Reasons	Solution
Drilling into the oval	Form threaded scratches	1.Using a suitable drill sets 2.Reduce the clearance angle 3.Check the drill bit tip angle is symmetrical with both sides length
	Produce fibrillation, vibration	1.Reduce the clearance angle 2.Web thinning 3.Shorten cemented carbide drill length , increased drill bit rigidity 4.Check cemented carbide drill angle grinding is correct or not 5.Check the fixture cemented carbide drill contact situation 6.Pre-drilled center hole 7.Improve the rigidity of the working machine
	The chip discharge is not easy	1.Increase the weekly amount of feed 2.Select the correct helix angle 3.Increasing the groove width ratio 4.Intermittent feed
Drilling tilt	Adverse when cutting	1.Using the appropriate drill sets 2.Reduce the cut when the weekly amount of feed 3.Pre-drilled center hole
	Drill rigidity is bad	Shorten cemented carbide drill length , increased drill bit rigidity
	Drill bit angle is wrong	Resharpening cemented carbide drill

Cemented Carbide Milling Processing Abnormal &Solutions

The cemented carbide milling is a rotary tool for milling, having one or more cutter teeth. Various cemented carbide milling cutter turn work intermittently cut the workpiece margin. Cemented carbide milling is mainly used in the milling machine the machining plane stairs, trench, forming surface and cut the workpiece.

Cemented carbide milling cutter abnormal causes and countermeasures

Situation	Reasons	Solution
Chipping	Large feed	Reduce feed
	Conventional milling (up cutting)	Climb milling (down cutting)
	Cemented Carbide Milling cutting edge is too sharp	The grinding cutting edge - necessary chamfer or fillet
	Vibration	Downward adjustment of spindle speed
	Cemented Carbide Milling cutter prominent too long	Projecting amount of the tool is adjusted to the minimum
	Milling cutter is not firmly clamped	Adjust the fixture accuracy
Wear	Cemented Carbide Milling cutting speed is too high	Reduce the cutting speed
	Feed amount is too small	Increase feed amount
	Conventional milling (up cutting)	Climb milling (down cutting)
	Material hardness is too high	Select special coating milling cutter

Cemented carbide tools:
Should try to choose the best rigidity, the maximum diameter of the slot length shortest and the shortest total length end mills.
Long edge cutter does not apply to the cavity milling, slotting or strong profiling - limited Rw 0.02D.
High-performance tool has a shorter processing time, a longer life.

Handle:
The shank is required to have sufficient clamping force and a sufficiently small rotary beating.
Recommended use for heavy cutting short and thick entities the shank or zero length collets shank.
The using entity shank, is not recommended to use the manual wrench.

Artifact:
Firmly clamp the workpiece will reduce tremor and deflection.

Machine:
To ensure the hilt achieve maximum run out accuracy and tool life, the spindle must be in the best condition.
To achieve the recommended speed and feed rate, the machine should have sufficient power.
To prevent damage to the workpiece or tool for low-power machines should reduce the amount of feed.

Cooling:
The jet law or liquid coolant to avoid swarf "secondary milling"
Cleaning and having an appropriate concentration to maintain the cooling liquid.

General recommendations:
Water-soluble oil or jet law: tool steel, tool steel, carbon steel or alloy steel;
Water-soluble oil: stainless steel, titanium, high temperature alloys, non-ferrous metals.

Method:
Recommends using climb milling.
Attention to detail, shank, jumping, balancing, fixture. Improve tool performance and extend tool life.

Cemented Carbide Milling Applications

Milling direction

During the milling process, the workpiece can be along or relative to the tool rotation direction feed, this will affect the cutting start and completion characteristics.

During climb milling (also called milling in the same direction), the workpiece is the same as the feed direction of the cutting zone of cemented carbide milling rotating direction. Chip thickness is gradually decreased from the start until the end of the incision is zero full length performing vicinity milling; performing inverse milling (also known as reverse milling), the workpiece feeding direction with the cutting zone, cutter rotation the opposite direction. The chip thickness is zero, and then gradually increases as the cutting process.

During conventional milling, cemented carbide milling blade to start from zero at the chip thickness cutting, which will produce high cutting forces, thus promoting the Cemented Carbide Milling and workpiece away from each other. Cemented Carbide Milling blade is forced into the incision, it is usually in contact with the hardened surface caused by the blade being cutting, both in the role of friction and high temperature cause friction and polishing effect. The cutting force is also easier to lift the workpiece from the work bench.

During climb milling, Cemented Carbide Milling blades begin cutting from the maximum chip thickness. This will reduce heat and weaken the hardened trend the lotus to avoid polishing effect. Application largest chip thickness is very favorable, and cutting force easier workpiece push Cemented Carbide Milling, Cemented Carbide Milling blade cutting action.

Cemented Carbide Broach Use - part1

Impact broaching quality and cemented carbide broach life, severe damage to broach cemented carbide broach the structure and use of common production problems. Longer ills and measures are summarized below:

1.To prevent cemented carbide broach fracture and tooth damage

Broaching cutter excessive force, broaches strength is not enough, is the damage cemented carbide broach the main reason. Caused by cutter tooth force many big factor, example: broach teeth liter excessive broach bending points of the cutting edge broaching margin uneven, radial round beating large cutter, prefabricated hole is too rough, materials internal hard spots, the workpiece strength is too high, the serious stick crumbs and chip flutes congestion and workholding skew. To cemented carbide broach smooth broach, the following measures can be used:

1) Requires the prefabricated hole accuracy IT8 IT10, surface roughness degree Ra ≤ 5 μm, prefabricated holes and positioning the end face perpendicularity deviation does not exceed 0.05mm.
2) Strict inspection of manufacturing precision broaches. The amount of tooth liter for outsourcing broaches, the chip space broach strength check.
3) Broaching the performance and difficult to machine materials, you can select the appropriate heat treatment to improve the workability of the material, often using high-performance materials cemented carbide broach or coating broach.
4) The custody, transport cemented carbide broach bending deformation and damage the cutter to prevent.

Cemented carbide drill selection step

Cemented carbide drill selection step

①To determine the hole diameter, depth and quality requirements
Consideration should also be given to the production of the economy and cutting reliability.

②Select drill type
Drilled select Step 2: Select for roughing and / or finishing hole drill. Check the suitability of the workpiece material drill hole quality requirements and provide the best economic.

③Select drill grades and geometries

④Select Tool shank type

Cemmented Carbide Drilling Cutting Parameters

Cemmented carbide drilling cutting parameters - cutting speed (VC), unit is m / min, is determined by the peripheral speed, cutting speed with spindle speed (n) to get. The spindle speed is represented by the number of revolutions per minute. In a turn, the drill circumference of π × Dc, Dc is the drill diameter. The drilling machining parameter of the cutting speed will change, which depends on the cross section of a cutting edge on the drill. From the drill center to the circumference, its speed is from zero to maximum. Recommended cutting speed is the highest speed of circumference.

Cemented Carbide Tool Drilling Technology

Cemented carbide tool drilling process includes the method of covering with a metal cutting tool on the workpiece cutting a cylindrical bore.

Cemented carbide tool drilling process and follow-up related to the process, such as trepanning, reaming, reaming and boring. Common to all these drilling process combined rotation main movement and linear feed motion. Sets of holes are mainly used for large diameter holes, unlike entity drilling as the need to consume a large amount of power. The set of holes drilled is not the whole diameter of the drilling hole, but in the circumference of the hole on drilling a ring. It is not all the materials are removed to chip form, but left a core surrounding the center, therefore, such a drilling process is mainly used for through-hole applications; reaming is to expand the existing hole with a special tool, this the drilling process is cutting out a large number of metal; finishing reaming of existing holes in the periphery of the hole. This drilling process will remove a small allowance, so as to achieve a better surface quality and small tolerances.

A base material of cemented carbide cutting tool

Metal cutting process, cemented carbide cutting tools cutting parts directly to complete the cutting work. Cemented carbide cutting tool material performance will directly affect the quality of the tool. Machining productivity and tool life of high end, the pros and cons of parts machining accuracy and surface quality largely depends on the choice of carbide cutting tool materials is reasonable.

Metal cutting process, cemented carbide cutting tools not only withstand a lot of cutting forces and high temperatures, but also to withstand shock loads and mechanical friction. Accordingly, the cemented carbide cutting tool materials must have a high hardness, high abrasion resistance, sufficient strength and toughness as well as good high-temperature heat resistance, chemical stability and thermal conductivity, and other aspects of performance. 

Cemented carbide slotting tool introduction

The cemented carbide slotting tool cutting part of high-speed steel and cemented carbide materials, alloy tool steel can also be used. Machining workpiece of ordinary steel and non-ferrous materials, commonly used in high-speed steel processing high hardness steel and cast iron workpieces are often used in cemented carbide. Since modular slotting tool manufacturing convenience, low cost, and a knife head can be processed into various shapes require sharpening, fixture replacement is very convenient, as long as the exchange of a knife head to the rough, finishing and forming process, so choose, priority modular slotting tool. However, modular slotting tool due to the restriction of the clamping heads apertures in the processing, when the narrow groove or blind holes can not be used.

Monolithic cemented carbide inserted knife from clamping heads restrictions, the head part made ​​smaller size as needed for the processing of the same size as the holes Arbor strength than modular plug cutter suitable for machining small holes, slots, blind holes (or empty knife slots small surface) and short foot surface. Integral slotting tool drawback is irreplaceable heads, each head size smaller, the entire knife was soon scrapped, not economic. 

Cemented carbide slotting tool types

Cemented carbide slotting tool many different types, mainly monolithic cemented carbide inserted knife and modular cemented carbide inserted knife two structures. The monolithic cemented carbide slotting tool of the cutter head with the shank integrally; modular cemented carbide slotting tool of the cutter head and the shank is divided into two parts, the shank can be done according to the machining situation thick and short, rigid, head free exchange, used widely.

Cemented carbide slotting tools processing nature is divided into and coarse cemented carbide slotting tool and fine cemented carbide slotting tool, knives, and cutters can be divided according to their use, forming knife. The knife used for coarse interpolation, or slotting polygon hole. The cutter is commonly used to slotting the rectangular-shaped groove and polygon holes. Forming knife needs sharpening made according to the shape of the workpiece surface, forming knife angle, arc and toothed shape into.

The type and purpose of the cemented carbide planer tool

Straight cemented carbide planer tool: Arbor Straight roughing.

The tip portion of the bent neck cemented carbide planer tool: arbor bent backwards under planing force, bending the elastic deformation does not bar the knife, cutting, grooving, and finishing with.

Partial knife: for processing angled flat, beveled, vertical.

The inner bore knife: machining the inner bore surface and the inner slot holes.

Cutter: used for grooving, cutting, planing the steps.

Curved cutter: T shaped groove, the side grooves, and the like.

Forming knife: Process the special shape of the surface. The planer tool blade shape is consistent with the workpiece surface. One time forming.

Elbow the cemented carbide planer tool: the left or right of the tip portion is bent, for cutting grooves.

Plane cemented carbide planer tool: coarse, fine planed with.

The rough cemented carbide planer tool: rough machining surface planer tool is usually powerful planer tool, to improve cutting efficiency.

Fine cemented carbide planer tool: fine machining planer tool is usually wide-bladed form to get the surface of the lower surface roughness value.

Cemented Carbide Planer Tools Introduction

Cemented carbide planer tool geometric parameters are selected by workpiece material, tool material, processing requirements. Table for cemented carbide planer tool reasonable geometric angles recommended values.

① fine planing, according to according to the flank face grind damper edges. Usually inverted arris angle αol after = -1.5 ° to 0, the chamfer width Bol = 0.1 to 0.5 mm.

②Machine power smaller, less rigid, the main declination election large value; Conversely, the election, small value. The arc transition between the blades of the main blade and vice should be adopted.

③The recommended values are available to choose from, depending on the specific circumstances choose.

Cemented Carbide Planing Inserted Tools Introduction - part2

Cemented carbide planing, slotting processing characteristics

Planing characteristics

①Planing main movement is planer tool relative to the workpiece cycle reciprocating linear motion, the feed movement workbench relative turret intermittent linear motion.

②Planing is interrupted cutting. Each reciprocating stroke planing planer tool larger impact will be cut into the workpiece, the processing requirements of the system has sufficient rigidity, workpiece and tool clamping firm; the main movement commutation must overcome a greater inertia, so planing cutting speed can not be too high; return trip planer tool is not involved in the planing, resulting in the loss of air travel, the productivity is low.

③Planing not only able to process plane, bevel, and uneven surfaces. Planing also processes a variety of surfaces, a wide range of technology.

④planing machining accuracy IT10 ~ IT7, the long rail surface for large machine tools can planing and grinding ". 

Cemented Carbide Planing Inserted Tools Introduction - part1

Cemented carbide planing, slotting processing characteristics

(1)Planing

Planing is generated between the tool and workpiece relative to the linear reciprocating motion of the workpiece surface to achieve a metal cutting method, mainly used for the machining plane, the grooves and the molding surface. Therefore, planing speed is impossible too high, lower planing productivity. Planed is smoother than milling machining. Planning precision is generally up IT8 ~ IT7, the surface roughness up to Ra6.3~ 1.6 μm, fine planing flatness up to 0.02/1000 and surface roughness of 0.8 ~ 0.4μm. Common planing machine is the Ngau Tau planing cutting planer and gantry planing planer.

Cemented carbide chaser introduction - part2

In the drawings, the tangential cemented carbide chaser install four of the same thread form tangential turning tools. The circular cemented carbide chaser is thread-round Cutters installed on Die.

Radial cemented carbide chaser is the most widely used, factory workers engaged Foreman will be frequently used.

Tap or circular die or the cutters itself are ribbed, so the shape of the individual cutting edge appears to be the same. Full week aliquots of each cutter staggered - one each pitch. For cemented carbide chaser, even if the respective cutter balance of the threads on each tooth, or will be shifted by 1/4 pitch.

Therefore, cemented carbide chaser mounted to the die shoe each knife tooth pitch of 1/4 stagger and sequence alignment. Therefore, must be marked on the cemented carbide chaser number 1 to 4. Write the right side of the right-hand thread, left-hand thread, of course is written on the left. If the order is disrupted, the processing thread will be chaos teeth. Daily custody also must put together a group of four to custody.

Cemented carbide chaser cutting part and tap as well as circular die is the same, but because of the chasers is more solid than taps and circular die, so their teeth will be slightly less.

cemented carbide chaser introduction - part1

So-called cemented carbide chaser is as if the four circular die tooth a separate, composed of a group of four.

Cemented carbide thread chasers use mounted in the die shoe. The finished thread die holder will automatically chaser opened from the outside, eliminating the need for the withdrawal of step with circular die processing thread.

Cemented carbide chasers with the workpiece contacting method, viewed from the outer radial, tangential and round three, can be divided.

CNC cemented carbide thread milling cutter

With the popularity of CNC machine tools, cemented carbide thread milling cutter technology, more and more applications in the machinery manufacturing. Thread milling of triaxial linkage by CNC machine tools or multi-axis, cemented carbide thread milling cutter the helical interpolation formation thread, thread cutter each for one week a circular motion in the horizontal plane, the linear movement in a vertical plane a pitch.Cemented carbide thread milling cutter have many advantages of high processing efficiency, high thread quality tool versatility, good processing safety, the user can be selected according to the own equipment, processing and object processing costs, processing batch, thread diameter and other conditions.

Comb-shaped cemented carbide thread milling cutter

Comb-shaped cemented carbide thread milling cutter is mainly used to processing with smaller teeth, shorter length cylindrical threaded processing of various taper thread.

Comb cemented carbide thread milling cutter constituted by a number of annular tooth pattern, the width is greater than the length of the workpiece, generally made ​​of a shovel tooth structure for processing short triangular thread dedicated milling. Their work is shown in Figure b. Workpiece revolution cutter relative to the workpiece axis to move a lead to all milling a thread.

Thread milling and turning threaded. Turning Threading is simple contour machining, cemented carbide thread milling cutter relative to the workpiece for cutting both sports, but also for the spiral motion, the spiral surface processing is the envelope surface made by cemented carbide thread milling cutter for cutting movement rotator relative spiral movement.

Disk-shaped cemented carbide thread milling cutter

The disk-shaped cemented carbide thread milling cutter is much like ordinary double angle cutters. It is mainly used for milling single-line and multi-line trapezoidal thread and worm.

Staggered cemented carbide thread milling cutter and workpiece axis angle ψ. As milling spiral groove for groove milling to reduce the interference in diameter should choose a smaller number of teeth more choices, in order to maintain stable milling. To improve the milling conditions on both sides of the cutter can be ground into a staggered, in order to increase the chip space, but the need for a complete tooth profile for the test.