Due to the large deformation of low-carbon steel chips, the chip thickness hDX is thicker than that of medium-carbon steel under the same conditions, so it is easy to break chips. Cutting practice has proved that with the same chip breaker parameters, the chip breaking range of low carbon steel is wider than that of medium carbon steel. Therefore, the same chipbreaker parameters as cutting medium carbon steel can be used when cutting low carbon steel.

A number of parameters must be taken into consideration when choosing the right carbide inserts. It is possible to find China carbide inserts manufacturers who provide quality material, but why take the chance? It is possible to find China carbide inserts manufacturers who provide quality material, but why take the chance?

Full-arc chipbreaker: Under the same rake angle and groove width, the full-arc chipbreaker has higher cutting edge strength, so it is suitable for larger rake angle and heavy-duty turning tools. There is the following approximate relationship between the truncated groove width Wn, arc radius Rn and rake angle γo:

K shape: The groove shape is an open half groove with a narrow front and a wide rear, also known as an inner slope. Contrary to the Y shape, the groove at B is narrow in width and small in depth, and the bottom of the groove has a positive edge inclination, so the chips are easy to flow away from the workpiece, forming tubular or ring-shaped spiral chips. Its chip breaking range is narrow, and it is mainly suitable for small cutting amount, finish turning and semi-finish turning, and it is also often used to guide chips to flow out of the hole during hole machining.

The chip is accompanied by curling during the outflow process, and the flow direction and curling of the chip determine the shape of the chip. When the chip curls upwards only along the chip thickness direction, the curling axis of the chip is parallel to the bottom surface of the chip, and the angle between them is θ = 0°. With the difference of the chip flow angle φλ, the chip shape formed is also different. It can be seen from Fig. 3-30 that when φλ=0°, there is no lateral flow of chips, and flat disc-shaped spiral chips (spring-shaped chips) are formed. When φλ≠0°, the chip curls upward while moving along its curling axis, that is, the chip moves in a spiral. When the value of φλ is large, if the moving distance of the chips is greater than or equal to the nominal width of the cutting layer while the chips are turning a circle, tubular spiral chips will be formed; if the value of φλ is small, the chips will move less along the curling axis, which is easy to form Cone-disk spiral chips (pagoda-shaped chips).

Based on the type of holder used, these inserts can cut grooves on both the outsides as well as the insides of a workpiece.

A carbide insert is a cutting tool is tool that is used for machining different metals, such as cast iron, steel, carbon, non-ferrous metals, and alloys with a high melting point. The inserts of a carbide cutter are indexable, which means they can be swapped, rotated, or flipped without affecting the geometry of the cutting tool.

The term milling insert refers to a piece of equipment that can be used to process materials such as steel and titanium without the fear of breaking the tool. The materials they help shape, they can straighten, shape, cut, and they can also cut metals such as steel, stainless steel, cast iron, non-ferrous materials, titanium, hardened steel, and plastic.

The carbide insert thread mill is the term used to describe a piece of cutting insert that is used to create an internal or external thread within a part. These are typically attached to a tool holder on a lathe or a turning centre, where they are normally used with tools.

There is no doubt that tungsten carbide inserts can withstand pressure when it comes to performance under pressure. In order to produce this durable, extremely strong metal, grains of tungsten carbide are cemented into nickel or cobalt to create cement. Tungsten carbide produces a material second only to diamond in terms of hardness.

In addition to thread mills and thread rolling, the use of thread inserts is another method for creating threads on a workpiece similar to thread milling. It is important to put these replaceable commodities in their proper places as replacements wear out.

Letter A, B, and T indicate the tolerances on the dimensions (* from nominal). Insert dimensions are given by Dimension A. Inscribed circle diameter is given by Dimension A. Dimension T is the thickness of the insert. As a result, dimensions A and B are the corresponding dimensions for pentagonal, triangle, and triangular shapes.

Carbide blades can be used to cut through wood, plastic, and metal, as well as a variety of other materials. Choosing the right blade for your material allows you to get smooth cuts using hard carbide tips. In terms of blades, the number of teeth, their shape, and if they are rounded or pointed, make a difference. It can be sharpened and reused for a long time when used correctly. On the contrary, the typical application of Ceramic Blades is to cut ceramic tile, porcelain marble, concrete, and masonry. They have a diamond coating that provides very clean and smooth cut results. Wet or dry applications are possible with this type of ceramic blade.

You can take advantage of inserts carbide in numerous possible ways. You can use carbide lathe inserts for machining various materials.

It is ultimately determined by such factors whether or not you will achieve satisfactory chip control and machining results.

Broken-line chipbreaker: It is formed by the intersection of two straight lines. The groove bottom angle θ replaces the function of the arc radius Rn described above. When the value is small, the curling radius of the chip is small. If the value of θ is too small, the chip will be blocked in the groove, which is easy to cause the knife to be hit; if the value of θ is too large, the curling radius of the chip will be increased and it will not be easy to break. The groove angle is generally recommended to be 110° ~ 120°.

Five digits indicate the diameter of the inscribed circle (I.C.) for all inserts that have a true I.C. such as Rounds, Squares, Triangles, Trigons, Pentagons, Hexagons, Octagons, and Diamonds.

In the sixth position, there is a significant one- or two-digit number representing the thickness of the insert in sixteenths of an inch. Whenever the thickness of a piece is a whole number: 1 – 1 * 16″; 2 – 1 * 8″; 3 – 3 * 16″; 4 – 1 * 4″; 5 – 5 * 16″; 6 – 3 * 8″; 7 – 7 * 16″; 8 – 1 * 2″; 9 – 9 * 16″; 10 – 5 ⁄ 8″.

Y shape: It is characterized by an open half groove with a wide front and a narrow rear, also known as an outward slope. The cutting speed of this groove shape A is high, the groove width is narrow, and the groove depth is small. The chips are curled here first, and the curl radius is small. At point B of the groove, the chips curl slowly, and the groove depth is large, and the bottom of the groove forms a negative edge inclination, which makes the chips easy to collide with the surface of the workpiece to form arc-shaped chips. When this kind of flute is used for medium back cutting ap, chip breaking is stable and reliable. When the ap is large, because the difference between the curling radii of A and B is too large, chips are easy to block.

Typically, carbide particles are bonded together with a metallic binder in order to create carbides that are cemented together. The carbide particles act as aggregates and the metallic binder acts as the matrix. Sintering means the combination of the carbide particles with the binder, so it is a technology that combines the particles with the binder. The binder in this process gradually enters the liquid phase, while the carbide grains (which have a much higher melting point) remain in the solid phase. In reality, the binder is cementing the carbide grains, creating a metal matrix composite with the distinct material properties that it requires. Taking advantage of the naturally ductile property of metal binders, to offset the characteristic brittle nature of carbide ceramics, is one of the best ways to increase their toughness and durability. The carbide parameters can be modified significantly in this manner within the sphere of influence of the carbide manufacturer, mainly depending on the grain size, the cobalt content, the dotation, and the carbon content.

It is intended to identify the eighths of an inch in the nominal size of the I.C. It will have one digit whenever the number of eighths of an inch in the I.C. is a whole number: 1 – 1 * 8″; 2 – 1 * 4″; 3 – 3 * 8″; 4 – 1 * 2″; 5 – 5 * 8″; 6 – 3 * 4″; 7 – 7 ⁄ 8″;

In the ninth position is a capital letter that indicates the hand of an insert: R – Right Hand; L – Left Hand; N – Neutral.

When the chips only have lateral (side) curls but no upward curls, the curling axis of the chips is perpendicular to the bottom surface of the chips (θ=90°), forming a ring-shaped spiral chip like a gasket.

A standard called ANSI B212.12-1991 describes nine different relief angle values. The angle between the flanks of an insert and the top surface of the insert is calculated by measuring the distance from 90° in a plane normal to the cutting edge. Typical relief angles are denoted as follows:

(2) Chipbreaker flute bevel. The bevel angle of the chipbreaker flute refers to the inclination angle of the chipbreaker relative to the main cutting edge. There are three forms, as shown in Figure 3-33.

Image

When the cutting depth is small (ap<1mm), if the above-mentioned chip breaker is used, it is not easy to break the chip. Because the chip breaker is too wide, the chips turn to the main cutting edge and flow out near the tool tip without passing through the bottom of the groove under the action of the arc of the tool tip and the minor cutting edge, and no additional curling deformation can be obtained. For this reason, the selected chip breaking groove shape and parameters must force the chip to curl or deform in the groove before it turns around the tool tip. As shown in Figure 3-34, the D-shaped chipbreaker can be used at this time, and it can be sharpened into a 45° oblique groove; the linear arc-shaped A-shaped chipbreaker can also be selected. When f=0.1mm/r, Desirable Wn=3f, hn=f, Rn=f/2.

With the combination of excellent heat resistance, better vibration and speed resistance, and the capability of cutting hard metals such as cast iron, ceramics are truly remarkable. Furthermore, this increase in the strength of the ceramic material also helps to prevent cracks from forming as a result of cutting the material.

If you are planning on using a carbide insert when you are cutting particulates or foam, you will have to make sure you choose the right insert. A preventative method can reduce the number of damage cases to the insert, as well as the machines as well as the workplace in general. Among the different styles, sizes and grades of cutting tools available in the market today.

When the grade is tough enough, the lack of strength in insert geometry can be compensated in part by the grade despite the lack of strength in the insert geometry.

The ceramic compound is added with small crystals of silicon carbide when whiskered ceramics are formed. There is a physical similarity between these crystals and whiskers, which is why this ceramic is called whiskered ceramic. With this kind of whisker, you can expect a machine to be a lot more resilient to vibrations and shocks.

The upcoming work will be easy for you once you have gained the knowledge of how to identify carbide inserts as a newbie. Carbide inserts are cutting tools that can be used to cut a wide variety of materials with high precision. Despite this, there are certain types of carbide inserts that can be used for cutting specific types of materials since not every insert can cut all types of materials. Thus, it is important for you to know what type of inserts are you using and when to use them.

The width and length dimensions of rectangular and parallelogram inserts are used instead of the I.C. The size of these inserts is indicated by a two-digit number. A first digit indicates how many eighths of an inch the insert is wide and a second digit shows how many fourths it is long.

Under the conditions of large cutting capacity and large feed rate (ap>10mm, f=0.6 ~ 1.2mm/r), due to the wide and thick chips, if C-shaped chips are formed, the cutting edge will be easily damaged, and the chips will splash and hurt people . Usually a full circular arc chip breaker is used and the arc radius Rn is increased to reduce the groove depth, so that the chips are rolled into a spring and broken on the transition surface, or fall by their own weight. According to the experience of processing large parts, the chipbreaker recommends the following parameters: groove width Wn=10f, arc radius Rn=(1.2~1.5)Wn; choose parallel or outward slope: τ=0°~6°. For the upward pressure indexable turning tool (see Figure 3-24), when the chip breaker is formed by the pressure plate, the bottom angle of the groove is θ=125°~135°.

In particular, ceramic inserts are much superior to carbide inserts when it comes to heat resistance. The ceramic insert category encompasses several variations, but, generally speaking, all of the options fall under the category of providing solutions for the machining of extremely hard metals. Since ceramic inserts are heat-resistant, they can be used for lower production times as they are capable of cutting continuously at higher speeds due to their heat resistance. Due to reduced production times and lower costs, ceramic inserts are a good choice.

(1) Chipbreaker truncated. The cross-sectional shape and size of the chipbreaker have an important influence on the chip breaking performance and cutting efficiency. The basic sectional shapes include straight-line circular arc, broken line, and full circular arc.

In addition to its high cost per unit, carbide is also very brittle, making it more susceptible to breaking and chipping when compared to other typical tool materials. Due to these factors, carbide cutting tips are often provided as small inserts within larger cutting tools that have steel hilts. The shank of the hilt is usually made of carbon, which is a more suitable material for the shank of the carbide cutting tip. As such, the carbide surface at the cutting interface is able to provide the benefits of using carbide without incurring the high costs and brittleness of making the whole tool from carbide. As with many of the modern lathe tools and endmills, most face mills these days have carbide inserts as well in them.

Image

The tungsten carbide used in cemented carbide is melted at an extraordinarily high temperature inside moulds. For saw blade tips, the moulds have pockets. These cemented carbide tips are then removed from the mould, placed on the saw blade tips, and brazed into place. A very sharp cutting edge is then created by grinding the tips. Except for the coating used on the tips, ceramic blades are formed the same way as carbide blades. There are also ceramic blades without teeth and with completely smooth edges. Blades with ceramic coating have very small diamonds embedded in the edge or tip. Diamond blades are commonly referred to as such because of this feature.

Carbide inserts are available in a wide range of types depending upon your application requirements. Below is a list of some of the major types of carbide inserts you are likely to encounter in your everyday life.

In determining the tool holder to enter the tool, the depth of cut, and the machine specifications, consider the cutting length.

The chip breakers of welded turning tools are ground when the tool is sharpened, while indexable turning tools are directly pressed into shape during the production of inserts.

When the seventh position contains letters, the 10th position will only be used. The number represents a nominal measurement of sixty-fourths of an inch in length: 1 – 1 * 64″; 2 – 1 * 32″; 3 – 3 * 64″; 4 – 1 * 16″; 5 – 5 * 64″; 6 – 3 * 32″; 7 – 7 * 64″; 8 – 1 * 8″; 9 – 9 * 64″; 10 – 5 ⁄ 32″.

Coatings are sometimes used in order to increase the lifetime of carbide inserts. Generally, coatings designed to increase a tool’s hardness or lubricity will also increase the tool’s lubricity. By coating a cutting tool, it will be possible for the cutting edge to pass cleanly through things without the material galling or sticking to it. Besides lowering the temperature associated with the cutting process, the coating will also increase the tool’s longevity by preventing the tools from getting stripped out. As a rule, the coating is deposited using either thermal CVD or mechanical PVD methods, both of which are usually done at lower temperatures, depending on the application.

Image

As the material integrity of ceramics has been improved, ceramics can be a viable alternative to carbide solutions, improving the life of the material to a similar duration as that of carbides.

There must be a simple system devised to categorise carbide inserts for their use since the sheer variety of carbide inserts on the market and their precision use require it. A series of letters and numbers are engraved on the centre of all steel cutting inserts, including carbide turning inserts. It refers to the ISO code system for turning tools that provides a simple method of identifying carbide inserts that can be used for narrowing the search for inserts. We discuss in this article a system of codes used to identify carbide inserts, and how I advise you to use the code system to identify your inserts.

An ideal nose angle would be a big one but it would be more complicated and require a lot more resources. Furthermore, it would be more likely to cause vibrations. As a result, a small nose angle will have a low cutting edge engagement and may not perform as well as a large angle. It is, therefore, more prone to the diverse effects of heat and has a heightened sensitivity to them.

Among the multitude of applications for which groove-making tools are relevant, there is a vast variety of hardware components of all types. These Carbide specialists specialize in determining the precise specifications required to perfectly suit the needs of each customer, regardless of whether they are parting off a smaller component or creating a deep groove with a large diameter. A Carbide insert can be grooved efficiently and expertly for extrusion grooving, internal grooving, face grooving, as well as parting. To maximize productivity and efficiency, you need to make sure that you choose the right tool. Every groove comes with its own set of challenges, no matter how wide or shallow it is. Additionally, every material used in the manufacturing of the component has its own set of properties and limitations. It is these three elements that truly determine how the ideal tool should be designed, sized, and rated for the job.

A turning tool body grips a replaceable insert which is attached to a lathe turret. Turning is typically done with a replaceable insert. Inserts for turning tools are manufactured using composite materials, coatings, and geometry features that provide high accuracy and high material removal rates.

(2) Cutting alloy steel. Generally speaking, the strength and toughness of alloy steel are improved to varying degrees compared with medium carbon steel, which increases the difficulty of chip breaking, so it is necessary to increase the additional deformation appropriately. Such as cutting 18CrMnTi, 38CrMoAl, 38CrSi and other alloy steels, it is recommended to use the outer inclined chip breaker, and the groove width Wn and arc radius Rn should be appropriately reduced.

Inserts made of cemented carbide are available in several sizes, shapes, and compositions that are used in various manufacturing methods on steels, cast iron, highly ferrous alloys, and nonferrous metals. In addition, machining metal parts more efficiently and with better finishes can be done when using carbide inserts. In addition to steel, stainless steel, hardened steel, cast iron, non-ferrous metals, titanium, and boring inserts are also good choices for applications.

(1) Cutting carbon steel. Under the condition of medium engagement and feed rate (ap=1~6mm, f=0.2~0.6mm/r), when cutting medium carbon steel with cemented carbide turning tool, if it is required to form C-shaped chips, it is recommended to use straight line For arc-shaped chip breaker, take arc radius Rn=(0.4~0.7)Wn, select outer inclined type τ=8°~10°, or choose parallel type, the width Wn of chip breaker is selected to be equal to or slightly larger than the specified The maximum ap value adopted, the feed range is about f=Wn/10~Wn/14.

The indexability of inserts is controlled by 14 tolerance classes. Capital letters indicate each class. Tolerances are indicated by the letters A, B, C, D, E, F, G, H, J, K, L, M, U, and N.

Additionally, these tools can be removed from the tool body, which means that the tools are not welded or brazed together. This type of tool can be used at high speed, which means you can create better surface finishes on your materials as a result of faster machining.

Make sure that you choose your carbide insert size according to the particular machining requirements and the availability of cutting tools in your position.

The seventh position indicates a radius or a facet. Radius is given as 1 * 64 of an inch: 0 – sharp corner (0.002″ maximum radius); 0.2 – 0.004″; 0.5 – 0.008″; 1 – 1 * 64″; 2 – 1 * 32″; 3 – 3 * 64″; 4 – 1 * 16″; 5 – 5 * 64″; 6 – 3 * 32″; 7 – 7 * 64″; 8 – 1 * 8″; 10 – 1 * 16″

The chip flow direction has an important influence on chip curling and breaking. The angle between the flow direction and the normal plane of the main edge is called the chip flow angle φλ, as shown in Figure 3-30. Due to many factors affecting the direction of chip flow, it is not yet possible to accurately predict the size of the chip flow angle. During right-angle free cutting, chips flow out along the vertical direction of the cutting edge, and the chip flow angle φλ≈0. When the bevel angle is free cutting (such as a wide-edged fine planer installed obliquely), the chip flow angle is approximately equal to the inclination angle of the working edge (φλ=λse). For general cutting, in addition to the main cutting edge, it is also affected by the secondary cutting edge. In general, the principle that chips flow out along the direction with the least energy consumption exists. Since the material at the root of the cutting zone is in a plastic state, small changes in the force acting on the chips will affect the flow direction of the chips. For example, the direction of the chip breaker, the obstacle of the workpiece, the geometric parameters of the tool, the wear of the tool, the built-up edge, the unevenness of the cutting amount and the material of the workpiece, etc., and even the length of the chip itself affects the direction of the outflow of the chip. The flow direction of chips is not only an important problem in the study of cutting mechanism, but also directly related to the control of chips. If the action direction of the chip breaker is not perpendicular to the chip flow direction, it will affect its chip breaking effect.

(3) Cutting difficult chip breaking materials. In metal cutting, some metal materials that are particularly difficult to break chips are often encountered, such as high-temperature alloys, high-strength steels, wear-resistant steels and stainless steels, as well as pure copper, oxygen-free copper, pure iron, etc. If the above-mentioned chip breaker is used, if the chip break is still not smooth, the shape of the main cutting edge can be changed, and a special chip breaker, vibration chip breaker, etc. can be used to achieve the purpose of chip breaking. For example, for the pure copper and oxygen-free copper chip breaking turning tools used in production, multiple arc-shaped grooves are ground on the back of the turning tool to make the main cutting edge into a corrugated washboard shape (rear washboard turning tool). Figure 3-55 shows a double-edge inclination cutting edge, that is, a second edge inclination is ground on the main cutting edge near the tip. The double-edge inclination can be used in conjunction with the ordinary outwardly inclined chipbreaker, the groove width Wn = 3.5~5mm, the outer bevel τ=6°~8°, the first edge inclination λs1=-3°, the second edge inclination λs2 =-(20°~25°), length Lλs2=ap/3. It is suitable for rough machining of stainless steel and has better chip breaking effect. The optimal range of cutting amount is: ap=4~15mm, f=0.1~0.35mm/r, vc=80~100㎡/min. This kind of turning tool has good tip strength, large chip curling radius, and most of them form conical disc-shaped spiral chips (pagoda chips) or short tubular spiral chips, but the radial force is 20% to 30% larger than that of single-edge inclination turning tools. It should not be used when the stiffness of the process system is poor.

The selection of carbide shapes should be based upon ensuring that it is a relatively essential tool for entering angles into the tooling process.

When the chips have both upward curl and side curl, the chip outflow angle φλ is not zero, and ring or conical spiral chips can be generated depending on the size of each parameter. When the upward or lateral curl of the chips is small, long strips or irregular banded chips are formed. If a chip breaker is made in front of the tool, the chips that flow out after the basic deformation (the deformation of the first and second deformation zones) can be curled again—additional deformation, making the chips harder and more brittle and easier to break. Therefore, curling and breaking of chips are closely related.

Unless otherwise specified, dimensions A and B refer to the distance measured along the bisector of the rounded corner angle and a gage roll of nominal I.C. For instance, if tolerance letter H shows 0.005″ on A, 0.0005″ on B, and 0.001″ on T, so dimensions (* from nominal) are: A, B, and T.

The radius of curvature rDX of the chips curling up is related to the parameters of the chip breaker. Taking the linear arc-shaped chipbreaker as an example, when the bottom surface of the chip is in contact with the shoulder of the chipbreaker, it is shown in Figure 3-31. The average radius of curvature rDX of chips curled in the chipbreaker can be calculated from the geometric relationship:

When choosing carbide shapes, consider the highest possible nose angle to ensure the longest possible life of the insert.

Linear arc-shaped chip breaker: This section is composed of straight lines and general arcs. The front of the turning tool is composed of a plane part close to the cutting edge. The basic parameters of the chip breaker are: width Wn=1~7mm, arc Radius Rn=(0.4~0.7)Wn, wedge angle βo≤40, negative chamfer width bn ≤fo, Rn and Wn are the main factors affecting chip shape, and the size of Rn directly affects chip curl radius.

A-shape: This groove shape is characterized by front and rear equal width and equal depth open half grooves, which is called parallel type. This groove shape can still obtain better chip breaking effect in the case of a wide variation range of ap. However, for an insert with a certain groove width, the chip breaking range is narrow, and the groove width should be determined according to the feed rate.

Fourteen standard types of insert are referred to using capital letters, and these variations include fixing holes, countersinks, and special features on rake surfaces.

A capital letter indicates 10 positions in the indexable insert as per the ANSI B212.4-2002 standard. There are ten positions (1-10), which define the characteristics of an insert as follows:

According to ANSI B212.4-2002, there was an additional capital letter O, which denoted other relief angles for design changes to indexable inserts.

With its high accuracy and high-performance indexable inserts, the Drilling and Hole Boring System is suitable for use on materials as diverse as aluminium and superalloys. With the drill body made of heat-treated steel that is very rigid, the nest for the insert is rigid and the flutes are straight, resulting in a long term life for the insert and an efficient chip removal process.

In order to protect and maintain the integrity of ceramic materials, precautions must be taken in the use of machines to keep excessive vibrations to a minimum. Ceramics are naturally more brittle than carbide alternatives. The ceramic compound is augmented with additional components that prevent this brittle tendency and increase its longevity.