CARBIDE INSERT QUOTATION,INDEXABLE CARBIDE INSERTS,CARBIDE INSERTS

When it comes to machining hard materials like steel, stainless steel, and cast iron, using the right cutting inserts is essential to achieve high precision and efficiency. Indexable cutting inserts are widely used in the industry for their versatility and cost-effectiveness. Here are some of the best indexable cutting inserts for hard materials:

1. Cubic Boron Nitride (CBN) Inserts: CBN inserts are specifically designed for machining hard materials like hardened steels and cast irons. CBN is one of the hardest materials available, second only to diamond. CBN inserts offer excellent wear resistance and thermal stability, making them ideal for high-speed machining applications.

2. Polycrystalline Diamond (PCD) VNMG Insert Inserts: PCD inserts are another excellent choice for machining hard materials. PCD is made from synthetic diamond particles sintered together under high pressure and temperature. PCD inserts offer superior hardness and wear resistance, resulting in longer tool life and improved surface finish.

3. Ceramic Inserts: Ceramic inserts are made from alumina, silicon nitride, or a combination of both. Ceramic inserts are known for their high heat resistance TCMT Insert and chemical stability, making them suitable for machining high-temperature alloys and hardened steels. Ceramic inserts are also highly wear-resistant and offer good surface finish.

4. Carbide Inserts: While carbide inserts are not as hard as CBN or PCD, they are still a popular choice for machining hard materials. Carbide inserts are made from a combination of tungsten carbide particles and a binder metal like cobalt. Carbide inserts offer good wear resistance and toughness, making them suitable for a wide range of machining applications on hard materials.

5. Coated Inserts: Many cutting inserts, including carbide, CBN, and ceramic inserts, are available with various coatings to improve their performance. Common coatings include TiN (titanium nitride), TiCN (titanium carbonitride), and AlTiN (aluminum titanium nitride). These coatings can help reduce friction, increase tool life, and improve chip evacuation when machining hard materials.

When selecting indexable cutting inserts for machining hard materials, it's essential to consider factors like cutting speed, feed rate, depth of cut, and workpiece material. It's also important to choose the right insert geometry, chip breaker design, and cutting edge preparation for optimal performance. By selecting the best indexable cutting inserts for hard materials, you can achieve higher productivity, better surface finish, and longer tool life in your machining operations.

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Chinese carbide inserts have gained a reputation for their high performance in high-precision machining applications. These carbide inserts are made of a combination of tungsten carbide and cobalt, which offers excellent hardness and wear resistance.

One of the key factors that contribute to the success of Chinese carbide inserts in high-precision machining is their superior cutting edge sharpness. The cutting edges of these inserts WCMT Insert are carefully ground to a very sharp angle, which allows for precise and clean cutting. This sharpness not only improves the overall quality of the machined parts but also helps in reducing resistance, resulting in higher machining speeds and increased productivity.

In addition to their sharp cutting edges, Chinese carbide inserts are also designed to have good chip control. This means that they are able to effectively produce and control the formation and evacuation of chips during the machining process. Proper chip control is crucial in high-precision machining as it prevents chip buildup, which can negatively impact the cutting process and cause defects in the final product. The chip control mechanisms in Chinese carbide inserts, such as chipbreakers and specialized geometries, ensure that chips are effectively managed, allowing for smoother and more efficient machining.

Chinese carbide inserts also offer excellent thermal and chemical stability, which is essential in high-precision machining. These inserts are able to withstand the high temperatures generated during machining without losing their hardness or becoming deformed. This stability not only ensures consistent performance but also helps in prolonging the overall tool life, reducing the need for frequent tool changes and increasing efficiency.

Another advantage of Chinese carbide inserts in high-precision machining is their versatility. These inserts are available in a wide range of geometries, sizes, and grades, allowing for precise customization to meet specific machining requirements. Whether it is turning, milling, or drilling, there is a Chinese carbide insert suitable for any high-precision machining operation.

With their sharp cutting edges, effective chip control, thermal and chemical stability, and versatility, Chinese carbide inserts prove to be a reliable choice for high-precision machining applications. They offer improved SEHT Insert productivity, higher machining speeds, and exceptional quality, making them a preferred tool for precision manufacturing in various industries.

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M&M Cut-O-Matic (Downey, California) slices custom blanks from various grades of tough-to-cut alloys and super alloys including aircraft-grade aluminum, stainless steel, Inconel and titanium. The company, which operates 5 to 6 days per week (16 to 19 hours per day), makes specialized cutoffs of large, thick workpieces utilizing two VM 2500 plate saws. Unlike standard bandsaws, plate saws hold the blade stationary while workpieces move against it. "Plate saws are expensive, but they justify their extra cost with better cutting control than standard bandsaws," says Steve Martin, vice president of M&M Cut-O-Matic. One plate saw cuts plates up to 42 inches wide, while the other cuts plates up to 20 inches wide. Bar stock is flame cut prior to bandsawing to create a pilot groove, thereby improving accuracy of the sawblade teeth on the entrance cut.

According to Mr. Martin, a very common side effect of heat treating tough-to-cut alloys is excess slag buildup.

The slag forms on the ends of workpieces and then hardens, which ruins blades and slows production. "Our conventional double-set carbide blades just couldn't penetrate the plates due to all the slag buildup," explains Mr. Martin. "Sometimes we had to stop, grind the part or hit it with a hammer to knock off the excess slag." Additionally, tough-to-cut alloys themselves can put tremendous stresses on conventional sawblade teeth, causing them to chip or break at the brazement. "As a result, we would have to stop for blade changes, which took 10 minutes each time, and that was affecting our productivity," says Mr. Martin.

Another cause for concern was that M&M's conventional carbide blades just weren't cutting fast enough to make up for the lost productivity during blade changes. They were running at cutting speeds of 80 sfm during blade break-in and at 90 to 100 sfm at full cutting speeds.

Faced with mounting problems, M&M searched for an appropriate solution that would increase blade life, bandsaw productivity and blade cutting speeds on its plate saw jobs.

As a first step, M&M contacted its distributor, Saw Service Of America, to see TNMG Insert if it knew of a cost-effective solution to the bandsawing problems. The distributor suggested Bahco Tools, Inc. (Scranton, Pennsylvania), a full line carbide bandsaw blade company. "We heard about the reputation and expertise of Bahco Tools in the field, so we gave them a call," says Mr. Martin. "A few days later we met with Bahco's technical experts. They brought with them several alternative carbide sawblades."

M&M engineers and Bahco Tool's technical experts worked hand in hand to find the right sawblade for the company's plate saws. They tried a Sandvik 3868 Triple-Set Xtra carbide-tipped coarse two-pitch blade, which was specifically designed to saw through large, thick, tough-to-cut bar stock. M&M tested the 3868 blade in conjunction with its conventional carbide blades over an 8-month period. After DNMG Insert just 6 months, M&M was convinced that the 3868 blade could perform better than its conventional carbides and at higher cutting speeds, so M&M standardized the 3868 on both VM 2500 plate saws.

Key to the 3868 blade's success is its Triple-Set combination tooth profile. It has a high, unset raker tooth with chamfered edges located dead center and two lower unchamfered teeth set left and right. The blade's tooth geometry allows for freer cutting and improved swarf clearance. Its deep gullets also help to minimize clogging and distribute feed forces more evenly among fewer teeth, thus maximizing penetration into workpieces. Additionally, the blade produces three distinct chips with significantly lower cutting forces than conventional carbide blades.

M&M's switch to the 3868 blade met all its expectations. The company cut bandsawing costs 30 to 35 percent on average by reducing the high frequency of blade changes on typical part runs. It can now run its machines 3 to 4 days straight without changing blades-getting 40 percent more blade life. Additionally, the carbide-tipped blade can be run at more than double the cutting speeds of its earlier carbide counterparts. As a result, M&M increased parts productivity on average by 40 percent on all its plate saw jobs. It also became a more competitive cutoff service and can now handle quoted customer turnaround times more efficiently.

M&M still utilizes conventional double-set carbide blades on its other bandsaw machines, which are designed to cut smaller workpieces. However, due to the success of the 3868 blade, M&M is working with Bahco to design a ?-inch pitch 3868 blade for those bandsaw machines.

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A reader recently used the “Ask an Expert” feature of our Micromachining Zone to ask about realizing the correct cutting parameters when using small milling tools.

Question

I struggle with the speeds and feed rates for "small" ball end mills (0.03125, 0.040, 0.0625) when cutting our typical tool steels such as P-20, A2, and H13. We are limited to a maximum spindle speed of 15,000 rpm. Do you concentrate on the sfm for finish end mills of the same diameter, or do you consider that the center of the ball is going to push harder for a given feed per tooth? Then, when lace cutting, the stepover becomes my next challenge. When I do feel confident with my feed and speed, I am unsure of my stepover or depth of cut.

Response from John Bradford, micromachining R&D team leader for Makino

Your question is one we see commonly. I would like to assure you that although 15,000 rpm will limit your capabilities, you still have a reasonable range of performance on tools down to 1 mm or so in diameter. However, I think you will find that your maximum feed rates will be limited by that speed, since the bottom line really is maintaining consistent chip load. Tools smaller than 0.03125 inch will certainly need higher rpm for effective feed rate and surface finish.

I would like to address your question by considering three important factors, the most important of which is the first one:

1. Runout

I am assuming that when you say you struggle with these smaller VBET Insert cutters, you are experiencing premature cutter wear and breakage. For small cutting tool applications, the most serious problem I see is that people assume the tool tip, and therefore each cutting tool flute, is rotating with no runout. Generally, standard tools in standard toolholders only provide for a minimum tool tip runout of 0.0005 inch. This is not generally a problem with larger tools, but is devastating for small tools, and will result in premature tool breakage and poor surface finish. People tend to respond to this by slowing down the feed rate to reduce chip load.

Recommendations:
● If you are using collet holders, be aware that standard ER collets are not sufficient for providing runout of less than 0.010 mm. UP-style collets may get you down to 0.005 mm, but that is still too much. Look for ultra TCGT Insert precision collet systems that have dynamic runout of 0.001 mm and below. (See this article.)
● Do not assume that the cutting flute is concentric with the shank of your tool. It is common to see flute runout of 0.010 mm or more relative to the tool shank. This is yet another issue that should be addressed, since it contributes to dynamic tool tip runout.

2. Cutting Tools

We typically recommend a carbide with TiCN or AlTiN coatings. For hardened materials, and for these small diameter tools, we recommend you do not use 4 flute cutters. Use 2 flute cutters, since the chip removal is much more efficient from the large gullet.

3. Depth of Cut

Generally, for carbide tools at small diameters, we use the following guidelines for maximum depths of cut:
● 30-40Hrc Materials—50% radial / 10% axial
● 41-50Hrc Materials—45% radial / 6% axial
● 51-60Hrc Materials—40% radial / 5% axial

For the corresponding chip load, although you should always check your tool supplier guidelines, I think you could use up to a 0.001 inch per tooth chip load to start. As a generic guideline, we recommend chip load relative to cutter diameter as follows:

Above 55Hrc
Roughing: 3% of cutter diameter
Semi: 2%
Finishing: 1%

Below 55Hrc
Rough: 5%
Semi: 3%
Finish: 1-2%

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Carbide inserts are widely VNMG Insert used in many industries, and they are designed to provide high-quality cutting performance for a variety of materials. In order to ensure that they are suitable for the application, it is important to understand the different grades of carbide inserts available. This article will explore the various grades of carbide inserts, as well as their applications.

The most common type of carbide insert is grade C, which is known for its excellent strength and durability. This grade is suitable for cutting a range of materials, including aluminum, brass, and plastic. It is also very resistant to wear and tear, making it a great choice for high-volume production.

Grade P is another popular grade of carbide insert. This grade is designed to provide a higher level of precision, making it a great choice for more intricate applications. It is also more resistant to heat and abrasion than other grades, making it ideal for Carbide Aluminum Inserts applications that involve high temperatures or exposure to harsh elements.

Finally, grade H is the highest grade of carbide insert available. This grade is designed to provide the highest level of precision and performance. It is often used in applications that involve extremely precise cuts, such as medical instruments or aerospace components. Grade H is also extremely heat-resistant, making it the ideal choice for applications that involve high temperatures.

Carbide inserts are a great choice for a variety of applications. Depending on the grade of carbide insert chosen, they can provide high-quality performance for a variety of materials. Understanding the different grades of carbide inserts available, as well as their applications, is key to ensuring that the correct grade is chosen for the job.

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