CARBIDE INSERT QUOTATION,INDEXABLE CARBIDE INSERTS,CARBIDE INSERTS

Carbide cutting inserts play a crucial role in modern machining processes, significantly enhancing efficiency and productivity. Made from tungsten carbide, these inserts are designed to withstand high temperatures, resist wear, and maintain sharp cutting edges over prolonged use.

One of the primary advantages of carbide cutting inserts is TNMG Insert their durability. Unlike traditional cutting tools, carbide inserts can endure the intense heat TNGG Insert generated during machining, which reduces the frequency of tool changes and downtime. This ability to maintain performance in extreme conditions allows manufacturers to operate at higher speeds, ultimately increasing production rates.

Another factor contributing to their efficiency is the precision offered by carbide inserts. These inserts provide consistent and accurate cuts, which leads to improved part quality. By achieving tighter tolerances and smoother finishes, carbide inserts minimize the need for secondary operations such as polishing, thus streamlining the manufacturing process.

Additionally, carbide cutting inserts are often designed with various geometries and coatings tailored for specific materials and applications. This versatility allows machinists to select the optimum insert for their particular needs, whether cutting through metals, plastics, or composites. The right insert can drastically reduce cutting forces, making machining easier on equipment and helping to extend the life of both the tool and the machinery.

Economic benefits also arise from using carbide cutting inserts. Their superior wear resistance leads to lower tooling costs over time. Although the initial investment in carbide inserts may be higher than that of conventional tools, the extended tool life and reduced need for replacements lead to significant cost savings in the long run.

Moreover, the faster cutting speeds and reduced cycle times associated with carbide inserts allow for greater production efficiency and higher output. In industries where time is money, the ability to reduce machining times without sacrificing quality can provide a competitive advantage.

In conclusion, carbide cutting inserts are indispensable in modern machining environments. Their durability, precision, and versatility not only enhance machining efficiency but also lead to economic benefits and improved part quality. As technology in manufacturing continues to evolve, the importance of innovative tooling solutions like carbide inserts will only grow.

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When it comes to tooling performance, the thickness of the insert can have a significant impact on the overall outcome. The thickness of the insert plays a crucial role in determining the strength, stability, and cutting ability of the tooling. Here are a few ways in which insert thickness can influence the performance of the tooling:

1. Strength: A thicker insert typically offers greater strength and durability compared to a thinner insert. This means that a thicker insert is less likely to chip, crack, or break during heavy-duty machining operations, leading to longer tool life and reduced tool replacement costs.

2. Stability: Thicker inserts provide better stability and support to the cutting edge, allowing for more precise and consistent cutting results. This results in improved surface finish and dimensional accuracy of the machined parts.

3. Cutting ability: The thickness of the insert also affects its cutting ability. Thicker inserts can withstand higher cutting forces and achieve higher metal removal rates compared to thinner inserts. This makes them more suitable for roughing operations and machining hard APKT Insert materials.

4. Vibration damping: Thicker inserts are better at dampening vibrations that occur during machining, leading to smoother cutting and improved tool life. This is especially important when working with long overhangs or unstable workpiece setups.

In conclusion, the thickness of the insert plays a crucial role in determining tooling performance. While thicker inserts offer greater strength, stability, cutting ability, and vibration damping, it is important to consider the specific requirements of the machining operation and choose the right insert thickness accordingly. By selecting Coated Inserts the appropriate insert thickness, manufacturers can optimize tooling performance, improve machining efficiency, and achieve better results.

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Cutting tool technology is advancing in both subtle and significant ways, and shops’ needs are changing as well. It is worth stepping back to take stock of these two important areas of change for cutting tools — namely, how they are designed and made, and how they are being used.

I recently spoke with John Kollenbroich, head of product management for cutting tool supplier Horn USA, about trends he is seeing. Our conversation was in the “IMTS spark” digital platform. Find the full conversation there. Here is bar peeling inserts an excerpt:

Modern Machine Shop: In grooving, turning and part-off tools, you are seeing more demand for tools providing coolant through the tool. There are a couple factors here we’ll talk about: more recognition of the need for this, plus a technology change in this tooling. First, why is through-tool coolant valuable, and why do you think shops are seeing greater need for it?

John Kollenbroich: Getting coolant to the cutting edge is critical for any manufacturing application. It helps in cooling the cutting zone, provides very needed lubrication, and can assist in breaking a chip. Many times, external lines are used to splash coolant near the work zone. Long Chips can easily interfere with this delivery method, possibly knocking the lines out of the way. Additionally, when tools need to be changed or indexed coolant lines fast feed milling inserts might be moved for better access to the tool. Then when the line is put back it is never the same as it previously was. Often times there is a give-and-take methodology used to cover areas being machined with this coolant, so all tools get some cooling, but none of them get ideal cooling. A coolant-through tool allows pinpoint accuracy with a specific direction of coolant pointed exactly at the cutting zone. This coolant supply is typically not affected by chip production, and occasionally, if high pressure is used, it can aid in breaking the chip. We also have applications where the coolant-through tool has shown marked improvement in tool life.

MMS: Through-tool coolant is available on cutters that couldn't offer it before. What has changed in the technology of tool manufacturing to make this possible?

JK: There’s been a big change is the ability to drill small-diameter holes very deep and do this in a production atmosphere. Part of this comes from the drilling machines being able to reach the necessary speeds and holders that provide superior clamping and runout. The other part comes from tools designed specifically for this drilling application. There are cases in manufacturing our tools where we are working with holes around 1 to 1.5 mm in diameter and 10 to 20 diameters deep. We’ve learned to design to take advantage of this. On a coolant-through tool, material could be added in areas that may need additional strength, allowing for the intersecting coolant ports to be drilled accordingly.

MMS: On machining centers in particular, speed is still increasing. Maybe the top speed available to machining center spindles hasn't changed all that much, but the use of higher-speed spindles continues to become more common. So, if the top speed hasn't gone up, the average speed in shops certainly has. How are cutting tool offerings responding to this? What aspect of tool engineering is responding to greater cutting speed?

JK: Machines and tools seem to have a back-and-forth dance in terms of which is leading. Currently, I believe cutting tools are in the lead, being able to withstand extremely high surface speed. This is mainly due to coatings and coating technology. Coatings continue to evolve, with more layers, and different material being used. This is something all tool manufactures are playing with on some level. The changes in coating technology is somewhat more limited, and not as many are playing in this arena. One process that comes to mind is “HiPIMS,” or high-power impulse magnetron sputtering. This process uses microsecond timing of extreme-power pulses. This allows the metal to ionize to nano size particles to be deposited on the tools. This process allows for greater adhesion and coating hardness, while maintaining great lubricity. Additionally, this process has greatly reduced compressive stresses. This reduction allows for smaller edge preps to be used, thus resulting in sharper tools. Think of compressive stresses as something pulling in all directions at the same time. If these stresses are pulling on a sharp edge it can pop the carbide right off. In order to circumvent this issue, edge preps are put on the tool. Basically, honing the edge, which is dulling the tool slightly. All tooling manufacturers must do this to properly support the coating. With HiPIMS you can have much smaller edge preps, and thus a sharper tool, for more free machining. Having a sharper tool allows for longer tool life. In testing against ourselves we have seen improvements of 50% using the HiPIMS coating technology.

MMS: Here is a topic that does not directly relate to the cutting edge, but still can connect to significant time savings: setup time. You are seeing something related to quick-change tooling and its adoption.

JK: Yes. Improvements in tool life add up. The increase allows for lower cost per part, but most of the time, these saving amount to limited returns. One of the reasons for this limiting factor is tool change time. This is a loss of machining time. Sometimes this loss is small, say 5 minutes to change a tool, other times it can be very large, say 30 minutes or more. If you are able to implement quick-change tooling, and consistently swap out new tooling in 1 to 2 minutes, your savings add up quickly. Swiss-style machines are one area where the saving can be very large. A typical insert change on a Swiss-style machine can be 15 minutes per tool. If you are changing out three tools per shift, that’s 45 minutes of non-production time. Now look at quick-change times of 2 minutes, 3 times a day, and you are at 6 minutes. That almost 40 minutes of production you have gained back. Considering a typical machine rate of $100, you just saved $65 that shift. Do that over a week, two shifts per day, and you have gained back almost 400 minutes, or one free shift of production. This could be the difference between needing to add equipment or better utilizing the machines you have.

MMS: Setup time reduction is a way to increase available machining capacity. Another important way that a growing number of shops is exploring is lights-out machining. The cutting tool plays a role here. What is the way to think about tools in unattended machining?

JK: Lights-out machining is a concept that many companies employ, but not all of them are successful. Sometimes there are only certain jobs that can be run due to issues within the machine. Sometimes shops slow down their tools in an attempt to increase tool life, hopefully reaching a full unattended shift. This is not always the correct approach. Tools are developed to cut within certain parameters, and tool life becomes predictable only within the proper window of operation. Once you have predictable tool life, regardless of time in the machine, you can begin to consider unattended operation. Also, another reason for running tools within the proper parameters is chip control. When a tool is underfed, many things can happen. You could be getting premature wear because of more rubbing than cutting, and you could be creating more of a stringy chip that could block coolant flow or cause issues for other tools.

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Walter introduces the TC388 and TC389 Supreme solid-carbide taps for threading hardened steel. According to Walter, the tools are designed to solve problems in blind-hole machining in particular, because reversing the tap during this process can cause torque peaks when the root of the chip is sheared off, resulting in tool failures.

Walter aims to solve this problem with the slot milling cutters TC388 Supreme (50-58 RC) and TC389 Supreme (55-65 RC) with its new patent-pending cutting geometries that fully shear off the root of the chip when reversing, thus minimizing torque peaks. This prevents fractures, prolongs the tool life and increases process reliability. Furthermore, the cemented carbide inserts new taps are coated using Walter’s new HiPMS coating technology, which is said to create a better surface finish and improve thread form quality. Lubrication with oil, which was often necessary until now, is no longer required; instead, standard water-based emulsions can be used, optimizing handling and saving additional machining costs. The TC388 and TC389 can be used for tapping both blind-hole and through-hole threads up to 2 × DN.

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The HC 400 horizontal machining center from Doosan is a compact, heavy-duty machine designed for OEMs and job shops. Featuring a Meehanite cast iron bed, linear roller guideway and inline spindle, the high-precision machine is capable of making heavy cuts on tough materials, the company says.

X-, Y- and Z-axis travels measure 23.62" × 22.05" × 22.24". Maximum cutting feed rate is 787 ipm with rapid traverse rates ranging to 1,574 ipm. Axes are driven by high-precision double-nut ballscrews CCMT Insert supported on both ends by angular thrust bearings. The double-pretension design is said to improve positioning repeatability. The HMC’s 35-hp, 10,000-rpm inline spindle is designed for high stock removal and deep drilling operations. Through-spindle coolant and an oil-cooled spindle chiller help to maintain a constant temperature at high speeds, reducing thermal growth and increasing cutting accuracy. The cam-type, swing-arm automatic toolchanger accommodates 60 tools and is said to provide 4-sec. chip-to-chip times.

The machining center’s telescopic cover inclined at a 30-degree angle directs chips into a trough to keep the area around the table clean, while high-velocity air jets clear chips while pallets are being changed. An automatic pallet changer with twin tapped pallets helps to minimize set-up Thread Cutting Insert time and increase productivity. Each pallet measures 15.7" × 15.7" and can handle a maximum load of 882 lbs. The FANUC 32i-A control features a 90-degree swiveling operator console for improved ergonomics. The handheld manual pulse generator with 10-ft. cord enables full access to the machine and controls access movement in increments of 1, 10 or 100 for easy fixture or workpiece alignment.

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