Nov. 27, 2024
Carbide tool inserts are crucial components in modern machining and metalworking processes. They offer superior cutting performance, longevity, and versatility, making them indispensable in various industrial applications. In this comprehensive guide, we&#;ll delve into everything you need to know about carbide tool inserts, including their types, applications, material properties, and how to select the right one for your needs.
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Carbide tool inserts are replaceable tips used in machining to cut, shape, and finish materials. They are made from carbide, a composite material consisting of tungsten carbide particles bound together with a metal, usually cobalt. This combination gives carbide inserts their renowned hardness and durability. They are used in turning, milling, and drilling operations across various industries, from automotive to aerospace.
Carbide tool inserts come in numerous shapes, sizes, and compositions, each suited for specific tasks and materials. Here&#;s a table to present the different types of carbide tool inserts:
Insert TypeShapeTypical ApplicationsCNMGDiamondGeneral turning, facing, and finishingTNMGTriangleMedium to heavy cutting, general purposeSNMGSquareRoughing, interrupted cuts, heavy-duty applicationsVNMGV-ShapedFinishing, profiling, and high-precision applicationsWNMGHexagonMedium to heavy roughing and interrupted cutsCCMTDiamondLight to medium cutting, high precision, and finishingDCMTDiamondFinishing and light cuttingSCMTSquareMedium to roughing, interrupted cuts, and heavy-duty applicationsRCMTRoundLight to medium turning, profiling, and high-speed cuttingAPKTRectangularMilling operations, high feed rates, and heavy-duty applicationsThe versatility of carbide tool inserts makes them suitable for a wide range of applications. Here&#;s a table to present carbide tool insert applications:
IndustryApplicationAutomotiveEngine components, transmission parts, suspension systemsAerospaceTurbine blades, landing gear, structural componentsMedicalSurgical instruments, implants, prostheticsOil & GasDrill bits, casing, downhole toolsManufacturingGeneral machining, tool and die making, mold manufacturingElectronicsMicro-machining, PCB manufacturing, semiconductor devicesUnderstanding the material properties of carbide tool inserts is essential for selecting the right one for your application. Here&#;s a table to present material properties:
PropertyDescriptionHardnessHigh resistance to wear and deformation, typically measured in Rockwell or VickersToughnessAbility to absorb energy and resist chipping or fracturingHeat ResistanceRetains hardness and strength at elevated temperaturesChemical StabilityResistant to corrosion and chemical reactions with work materialsThermal ConductivityEfficiently dissipates heat generated during cuttingCarbide tool inserts are made from different grades of carbide, each offering unique characteristics. Here&#;s a table to present composition, properties, characteristics, etc.:
GradeCompositionCharacteristicsC197% WC, 3% CoHigh wear resistance, used for non-ferrous materialsC294% WC, 6% CoVersatile, good for ferrous and non-ferrous materialsC390% WC, 10% CoHigher toughness, used for interrupted cutsC486% WC, 14% CoVery tough, suitable for heavy-duty applicationsC581% WC, 19% CoHighest toughness, used for very heavy-duty applicationsP% WC, 8% Co, TiC/TaC additivesGood for high-speed finishing of steelP% WC, 11% Co, TiC/TaC additivesGeneral purpose turning and milling of steelP% WC, 15% Co, TiC/TaC additivesRoughing and interrupted cuts in steelK% WC, 6% Co, Cr3C2/TaC additivesFinishing and semi-finishing of cast ironK% WC, 10% Co, Cr3C2/TaC additivesRoughing of cast iron and non-ferrous metalsHere&#;s a table to show hardness, strength, and wear resistance of carbide tool inserts:
GradeHardness (HV)Toughness (MPa)Wear ResistanceCVery HighCHighCMediumCMediumCLowPHighPMediumPLowKHighKMediumCarbide tool inserts are available in various specifications, sizes, and shapes. Here&#;s a table to show specifications, sizes, shape, standards:
ShapeSize (mm)Thickness (mm)ISO StandardANSI StandardTriangle12, 16, 203.97, 4.76, 6.35ISO ANSI B212.4Diamond11, 13, 162.38, 3.18, 4.76ISO ANSI B212.4Square12, 16, 203.97, 4.76, 6.35ISO ANSI B212.4Round16, 20, 254.76, 6.35, 9.53ISO ANSI B212.4Rectangular10, 15, 202.38, 3.97, 4.76ISO ANSI B212.4Selecting the right supplier is crucial for ensuring the quality and performance of carbide tool inserts. Here&#;s a table with suppliers and pricing details:
SupplierLocationPrice Range (USD)ContactKennametalUSA10-50 per insertwww.kennametal.comSandvik CoromantSweden15-60 per insertwww.sandvik.coromant.comIscarIsrael12-55 per insertwww.iscar.comSeco ToolsSweden13-58 per insertwww.secotools.comMitsubishiJapan14-60 per insertwww.mitsubishicarbide.comKyoceraJapan10-45 per insertwww.kyocera.comSumitomoJapan11-50 per insertwww.sumitomotool.comWalter ToolsGermany13-55 per insertwww.walter-tools.comTungaloyJapan12-54 per insertwww.tungaloy.comCeratizitLuxembourg15-60 per insertwww.ceratizit.comChoosing the right carbide tool insert involves considering several factors, including the material being machined, the type of machining operation, and the specific requirements of the job. Here&#;s a table to show how to select the right carbide tool inserts:
FactorConsiderationsMaterial to be MachinedHardness, toughness, and abrasiveness of the materialType of OperationTurning, milling, drilling, finishing, roughingCutting SpeedHigher speeds require inserts with better heat resistanceFeed RateHigher feed rates may require tougher insertsDepth of CutDeeper cuts may require inserts with higher toughnessMachine Tool CapabilityPower, rigidity, and speed of the machine toolSurface Finish RequiredFinishing operations may require inserts with finer grain structureTool Life ExpectationsLonger tool life may justify higher initial costHere&#;s a table comparing advantages and limitations of carbide tool inserts:
AdvantagesLimitationsHigh HardnessCan be brittle, susceptible to chippingExcellent Wear ResistanceHigher cost compared to high-speed steel (HSS)Ability to Maintain Cutting EdgeLimited toughness compared to ceramicsHigh Cutting SpeedsRequires precise handling and setupVersatility in ApplicationsSpecialized inserts needed for specific tasksWhat are carbide tool inserts used for?
Carbide tool inserts are used for cutting, shaping, and finishing various materials in machining operations such as turning, milling, and drilling.
Why are carbide inserts preferred over HSS tools?
Carbide inserts are preferred because they offer superior hardness, wear resistance, and the ability to maintain cutting performance at higher speeds and temperatures compared to high-speed steel (HSS) tools.
How do I choose the right carbide insert for my application?
Selecting the right carbide insert involves considering the material being machined, the type of machining operation, cutting speed, feed rate, and the required surface finish. Refer to the selection table provided above for detailed guidance.
What are the different grades of carbide inserts?
Carbide inserts come in various grades, each tailored for specific applications. For example, C1 is highly wear-resistant for non-ferrous materials, while P20 is a general-purpose grade for turning and milling steel.
Can carbide inserts be resharpened?
In most cases, carbide inserts are not resharpened. Instead, they are replaced once worn out or damaged, as resharpening can compromise their precision and performance.
How long do carbide inserts last?
The lifespan of carbide inserts depends on factors such as the material being machined, cutting conditions, and the type of operation. Proper selection and usage can maximize their longevity.
Link to Guangzhou Ruiyi Technology Co., Ltd.
What are the advantages of using coated carbide inserts?
Coated carbide inserts offer additional benefits, including increased wear resistance, reduced friction, and extended tool life, particularly in high-speed and high-temperature applications.
Where can I buy carbide tool inserts?
Carbide tool inserts can be purchased from various suppliers such as Kennametal, Sandvik Coromant, Iscar, Seco Tools, and many others. Refer to the supplier table for more details.
Are there different shapes of carbide inserts?
Yes, carbide inserts come in different shapes like triangle, diamond, square, round, and rectangular, each suited for specific cutting tasks and applications.
What is the cost range for carbide inserts?
The cost of carbide inserts varies based on the supplier, grade, and specific type. Prices generally range from $10 to $60 per insert. Refer to the supplier pricing table for detailed information.
In conclusion, carbide tool inserts are essential for efficient and precise machining operations. By understanding their types, applications, properties, and how to select the right insert, you can optimize your machining processes and achieve superior results.
know more Tungsten carbide
When machining, selecting the correct carbide insert shape is crucial for optimizing performance, tool life, and achieving the desired results. Each insert shape has its unique strengths and applications. Here&#;s a guide to help you choose the suitable carbide insert based on your specific machining needs, using information from Millstar&#;s Total Carbide Insert Solutions.
Strength and Economy: Square inserts offer a very strong 90° corner, providing excellent economy with up to 8 cutting edges on double-sided inserts.
Best For: These inserts are ideal for rough facing operations, particularly on castings, forgings, and rough-sawed blanks.
Limitations: Square inserts are unable to turn or face up to a shoulder unless used in a toolholder with a minimum 5° lead angle. High radial forces can push against the workpiece during turning, so they should always be used in a stable setup.
Versatility and Popularity: The 80° diamond insert is the most popular shape due to its versatility. It has a strong cutting edge and secure seating in the insert pocket.
Best For: These inserts are suitable for turning and facing operations, with opposite 100° corners providing maximum economy in roughing applications.
Limitations: With only 5° of clearance between the trailing side of the insert and the workpiece, chip jamming can occur when boring.
Economy: This insert offers increased economy compared to CNMG-style inserts.
Best For: These inserts are typically used for moderate cut and feed rate depths, making them a good choice for general-purpose machining.
Limitations: The seating is not as stable as CNMG-style inserts, and they cannot handle as deep a depth of cut.
Versatility: Triangle inserts are highly versatile and suitable for turning, facing, boring, copy turning, and basic profiling.
Best For: They are an excellent choice for general boring due to their stable seating in the boring bar pocket and extra side clearance, which reduces the risk of chip jamming.
Limitations: The edge strength of triangle inserts is weaker than 80° diamond-shaped inserts.
Profile Turning: The 55° diamond insert is generally the first choice for profile or copy turning applications, capable of &#;in-copy&#; (plunge turn into a smaller diameter) at a 30° angle.
Best For: These inserts are ideal for machining near the tailstock or live center.
Limitations: They have weaker edge strength than triangle inserts, and the cost per edge is higher than most other turning inserts.
Intricate Machining: The 35° diamond insert is the go-to choice for intricate shape copy turning and can &#;in-copy&#; at angles up to 49°.
Best For: It is ideal for working extremely close to the tailstock or live center.
Limitations: This is the weakest insert shape in terms of edge strength, so the depths of cut and feed rates must be lighter. It also has the highest cost per edge.
Conclusion
Choosing the right insert shape is critical to the success of your machining operation. By understanding the strengths and limitations of each insert shape, you can optimize your machining processes for better efficiency, accuracy, and cost-effectiveness.
At Epic Tool, we offer a comprehensive range of carbide inserts from the Total Carbide brand from Millstar Canada, designed to meet the diverse needs of machinists. Contact us today to learn more about how our carbide insert solutions can enhance your machining operations.
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