CARBIDE INSERT QUOTATION,INDEXABLE CARBIDE INSERTS,CARBIDE INSERTS

Cermet inserts are widely Cutting Inserts used in machining operations due to their excellent wear resistance, toughness, and high-temperature stability. However, despite their many advantages, there are common mistakes that operators make when using cermet inserts that can lead to suboptimal performance and reduced tool life. Understanding these mistakes and how to avoid them is crucial for achieving efficient machining processes.

One of the most common mistakes is improper selection of cutting parameters. Cermet inserts have specific recommended cutting speeds, feed rates, and depths of cut based on the material being machined, the type of operation, and the machine setup. Failure to adhere to these recommended parameters can result in premature wear, chipping, or even catastrophic failure of the insert.

Another frequent error is inadequate tool setup and alignment. Proper tool positioning, including correct insert seating and clamping, is essential for achieving accurate and consistent machining results. Misalignment can lead to uneven cutting forces, vibration, and poor surface finish, ultimately affecting the overall quality of the machined part.

Furthermore, insufficient coolant or improper coolant application can negatively impact cermet insert performance. Cermet materials are sensitive to heat buildup during machining, and proper cooling is essential to dissipate heat and prevent thermal damage to the insert. Using the appropriate coolant type, concentration, and delivery method is crucial for maximizing tool life and maintaining machining efficiency.

Failure to properly maintain cermet inserts is another common mistake. Regular inspection for wear, damage, or edge chipping is necessary to identify any issues early and prevent potential machining problems. Additionally, timely replacement of worn or damaged inserts is essential to avoid tool breakage and Cermet Inserts maintain consistent machining quality.

Lastly, inadequate operator training and experience can contribute to mistakes when using cermet inserts. Operators must receive comprehensive training on insert selection, tool setup, cutting parameters, and maintenance procedures to ensure optimal performance and productivity. Continuous education and skill development are essential for mastering the intricacies of cermet machining and achieving the best possible results.

In conclusion, while cermet inserts offer numerous benefits for machining applications, they are susceptible to various common mistakes that can compromise performance and efficiency. By understanding and addressing these mistakes, operators can maximize the potential of cermet inserts and achieve superior machining results.

Fullerton Tool Co., a manufacturer of solid carbide cutting tools located in Saginaw, Michigan, has announced the acquisition of Carbro Corp., a manufacturer of solid carbide rotary tools located in Lawndale, California. Following the acquisition, Carbro Corp. will operate as Carbro LLC.

Carbro will continue to operate as its own entity, as well as partner with Fullerton to create strategic partnerships aimed at the aerospace market. This acquisition and partnership will allow Carbro to continue to provide its existing products and services.

“Carbro and Fullerton will continue to build upon their existing product lines and reputations and together will create strategic partnerships to better service specialty markets as well as our customers,” says Patrick TNGG Insert Curry, president and co-owner of Fullerton Tool. “I am excited for the future with both of these companies and how this partnership will DCMT Insert impact the manufacturing industry.”

Variations in workpiece material and/or cutting tools will often require operators to change cutting conditions (mostly spindle speed and feed rate) during a production run. Most manufacturing companies do allow their CNC people to make these changes as they are required to do so. And for the most part, changing speeds and feeds in a program is relatively simple. Many tools have but one speed word (S) and one feed rate word (F) per tool. In this case, it is quite easy for an experienced operator to find and scan to the one or two words in the program that must be changed.

While an experienced operator may be able to change cutting conditions with relative ease, a novice may find it more difficult. And if the novice changes the speed or feed for the SNMG Insert wrong tool, the results could be disastrous. If you expect operators to change cutting conditions on a regular basis, you should do everything you can to make the task as simple as possible.

Consider those machining operations that have more than one speed or feed word. Maybe an operator is plunging into a slot in the Z axis with an end mill at one feed rate, but when he must begin milling in the X and Y axes, he also must switch to another feed rate. This, of course, requires two feed rate words per slot.

If there are 50 slots to mill, that equals 100 feed rate words for this tool.

Changing the feed rate for Surface Milling Inserts this tool becomes much more difficult for the operator. One way to simplify the task of changing cutting conditions is to start the program with a series of variables that specifies the various spindle speeds and feed rate words for all tools in the program. Be sure to place a nice documenting message next to each variable to clarify what the variable represents. During each tool’s specification of speed and feed, you will simply reference the value of the appropriate variable. Here is an example given in the custom macro B format.

O0001 #100=1200 (Speed for center drill)
#101=3.5 (Feed rate for center drill)
#102=800 (Speed for 1/2" end mill)
#103=2.25 (Plunge feed rate for 1/2" end mill)
#104=5.5 (X, Y feed rate for 1/2" end mill)
#105=800 (Speed for 1/2" drill)
#106=7.0 (Feed rate for 1/2" drill)
N005 T01 M06 (Place center drill in spindle)
N010 G54 G90 S#100 M03 T02 (Select coordinate system and absolute mode, start spindle, and get next tool ready)
N015 G00 X1.0 Y1.0 (Move to first hole position in X, Y)
N020 G43 H01 Z0.1 (Instate tool length compensation and move to approach position in Z)
N025 G81 R0.1 Z-0.12 F#102 (Drill hole)
N030 G80 (Cancel cycle)
N035 G91 G28 Z0 M19 (Return to tool change position and orient spindle)
N040 M01 (Optional stop)
N045 T02 M06 (Place end mill in spindle)
N050 G54 G90 S#102 M03 T03 (Select coordinate system, absolute mode, start spindle, get next tool ready)
N055 G00 X3.5 Y2.0 (Move to first XY position)
N060 G43 H02 Z0.1 (Instate tool length compensation, move to approach position in Z)
N065 G01 Z-0.25 F#103 (Plunge first slot)
N070 X5.5 F#104 (Mill first slot)
N075 G00 Z0.1 (Retract)
N080 X3.5 Y3.0 (Move to second slot)
N085 G01 Z-0.25 F#103 (Plunge slot)
N090 X5.0 F#104 (Mill second slot)
N095 G00 Z0.1 (Retract)

Although this column only presents a portion of the program, it should be enough to illustrate how the technique works. Notice the list of variables that begin the program (#100 through #106 are variable specifications in custom macro B).

Next to each variable, there is a clarifying message specifying exactly what the variable represents. #100, for example, is the speed for the center drill. In line N010, notice that the S word references the current value of #100, which is 1,200. The spindle will start at 1,200 rpm. The same technique is used in line N25 for feed rate. Notice how easy this technique makes it for the operator to change cutting conditions, even for the end mill that must machine multiple slots.

This TungTriShred flute mill on display at Tungaloy’s product seminar is equipped with chip-splitting inserts whose wavy edges break chips and reduce machining load. The inserts are staggered behind one another to clean up the grooves left by the one Carbide Aluminum Inserts before, producing a good surface finish.

The key takeaway from Tungaloy’s April 6 seminar introducing the TungForce cutting tool line is this: The only way for tooling to really reduce total machining costs is by increasing productivity.

In terms of total investment, the lion’s share of machining costs (as much as 75 percent) are directly related to time, including labor and the cost of running the machinery. According to presenter Jacob Harpaz, president and CEO of the IMC Group which owns Tungaloy, tooling costs comprise a mere 3 percent of total investment; that means that even if you extended tool life twofold, you’d still only cut 1.5 percent of the total cost of machining. On the other hand, if you can reduce the time of production—by improving feed rates and cutting speeds, for example—then you can potentially make a much bigger dent in the aggregate.

This is the philosophy behind the more than 1,050 new products included under the TungForce banner. Mr. Harpaz introduced the line of tools for turning, grooving, drilling and milling to a crowd of over 500 machinists, distributors and salespeople in Chicago, Illinois, explaining how these tools’ coatings and geometries enable higher feeds and speeds to produce parts faster.

Over 500 people attended the seminar in the Sheraton Grand Chicago hotel.

The TungForce line includes grades with CVD- and PVD-applied coatings that prolong tool life to make up for increases in maximum cutting speeds. A post-treatment process is said to reduce thermal cracks that usually form in the coatings after the high-temperature deposition process, which further boosts tool life.

Meanwhile, the inserts’ geometries are designed to enable faster feed rates with VBMT Insert chipbreakers and splitters. For the milling tools, positive rake angles and secure insert clamping enable faster, shallower cuts for roughing operations.

The horizontally-poised tools shown here are part of the DeepTriDrill series of indexable gundrills. Chip splitters allow for higher feed rates, and guide pads promote circularity and straightness, even with the series’ longest tool measuring 59 inches (1,500 mm)—90 times diameter. 

Look for product releases on individual series within the TungForce line in upcoming issues of the magazine.