High-speed cutting tools for high-hardness steel (HRC40~70) can be metal ceramic tools, ceramic tools, TiC-coated carbide tools, PCBN tools, etc. Metal ceramics can be metal ceramics with TiC as the basic component and TiN added. Its hardness and fracture toughness are roughly equivalent to those of cemented carbide, while its thermal conductivity is less than 1/10 of that of cemented carbide, and it has excellent oxidation resistance, adhesion resistance and wear resistance. In addition, it has good mechanical properties at high temperatures and low affinity with steel, which is suitable for medium- and high-speed (about 200m/min) mold steel SKD processing. Metal ceramics are particularly suitable for grooving. Ceramic tools can be used to cut workpiece materials with a hardness of HRC63. If the workpiece is quenched before cutting, “cutting instead of grinding” can be achieved.

Cast aluminum alloys use different tools according to the different base Si content. For cast aluminum alloys with Si content less than 12%, K10 and Si3N4 tools can be used. When the Si content is greater than 12%, PKD (artificial diamond), PCD (polycrystalline diamond) and CVD diamond coated tools can be used. For silicon-over-silicon aluminum alloys with Si content of 16%~18%, it is best to use PCD or CVD diamond coated tools, with a cutting speed of 1100m/min and a feed rate of 0.125mm/r.

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We live in a time when every minute matters and quality can’t be compromised. Because of this, we have processes set up and employees with the expertise to make the delivery time you need and can depend on. Speed, accuracy and quality craftsmanship are things we pride ourselves in when working on your project.

or castings, when the cutting speed is greater than 350m/min, it is called high-speed machining, and the cutting speed has a great influence on the selection of tools. When the cutting speed is lower than 750m/min, coated carbide and metal ceramics can be used. When the cutting speed is 510~2000m/min, Si3N4 ceramic tools can be used. When the cutting speed is 2000~4500m/min, CBN tools can be used. The metallographic structure of the casting has a certain influence on the selection of high-speed cutting tools. When the cutting speed is greater than 500m/min for processing castings dominated by pearlite, CBN or Si3N4 can be used.

Although we always hope to obtain tool materials with both high hardness to ensure the wear resistance of the tool and high toughness to prevent the tool from breaking, the current technological development has not yet found such superior performance tool materials, and we cannot have both. Therefore, we will choose more suitable tool materials according to needs in practice. The toughness of the tool material is given priority in rough machining; the hardness of the tool material is given priority in fine machining. Of course, people also expect to obtain better results by processing at ultra-high cutting speeds.

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The cutting speed has a great influence on the surface quality of steel. According to research, its optimal cutting speed is 500~800m/min. At present, coated carbide tools, metal ceramic tools, non-metallic ceramic tools, and CBN tools can all be used as tool materials for high-speed cutting of steel parts. Among them, coated carbide tools can use cutting fluid. The wear resistance of TiN coated tools produced by PVD coating method is better than that of coated tools produced by CVD coating method, because the former can well maintain the shape of the cutting edge, so that the processed parts can obtain higher precision and surface quality.

Cermet tool county currently occupies a large market share. The metal ceramics based on TC-Ni-Mo have good chemical stability, but poor bending strength and thermal conductivity. They are suitable for finishing with small feed and small cutting depth at a cutting speed of 400~800m/min. Metal ceramics with TiCN as the matrix and less molybdenum and more tungsten in the binder combine strength and wear resistance. TiN is used to increase the toughness of metal ceramics. The cutting depth of steel or cast iron can reach 2~3mm.

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Specialty Tool & Mold Inc. is a manufacturer of custom thermoform molds and trim tooling. We have been located in Grand Rapids, Michigan since 1967. We serve the needs of the food and consumer packaging industries as well as tooling for automotive appliques. We cover both the contact heat cut-in-place and radiant heat plug assist in-line process. In addition to single edge dies and match metal dies for the thermoform process, we also specialize in compound dies for the gasket cutting industry.

When cutting 45 steel with a quenched hardness of HRC48~58, the cutting speed can be 150~180m/min, the feed rate is 0.3~0.4min/r, and the cutting depth can be 2~4mm. AI203-TiC ceramic tools with a particle size of 1um and a TiC content of 20% to 30% can be used to process high-hardness steel with high anti-stripping performance at a cutting speed of about 100m/min. When the cutting speed is higher than 1000m/min, PCBN is the best tool material, and PCBN tools with a CBN content greater than 90% are suitable for processing hardened tool steel (such as H13 tool steel with HRC55).

When ferrite is dominant, due to diffusion wear, the tool wear is serious. Regardless of the use of CBN, ceramic tools should be used. For example, when the bonding phase is metal Co, the average grain size is 3um, and the CBN content is greater than 90%~95%, BZN6000 is suitable for processing gray cast iron with high ferrite content when V=700m/min. Amborite blades with a ceramic (AIN+AIB2) bonding phase, an average grain size of 10um, and a CBN content of 90%~95%, when processing gray cast iron with a high pearlite content, when the cutting speed is less than 1100m/min, the tool life increases with the increase of cutting speed.

Advanced composite materials used in aerospace used carbide and PCD in the past. The cutting speed of carbide was limited. However, at a high temperature of more than 900℃, the PCD blade melts at the welding point with the carbide or high-speed steel cutter body, and ceramic tools can achieve high-speed cutting of about 300m/min.

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Located just 10 minutes south of Grand Rapids, MI our facility is right in the heart of the  Midwest. With Gerald R. Ford International airport located less than 7 miles away and various trucking and logistics options are available. We are ready to ship land, air or sea.

Meeting and exceeding our customers’ needs is our number one priority. Regardless, if your project is complicated or simple, it is of high value to Specialty Tool & Mold Inc. and we can ensure total satisfaction with your project.

The employees at Specialty Tool & Mold Inc. are experts in their field. They are an integral part of a team approach when working on your project. With our diverse experience in manufacturing, we have the ability to think “outside the box” when providing tooling solutions. This is key to producing exceptionally designed, engineered and manufactured tooling.

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Silicon nitride ceramics (Si3N4) can also be used for processing Inconel718 alloy. It is generally believed that the best cutting conditions for machining Inconel718 with SiC whisker reinforced ceramics are: cutting speed 700m/min, cutting depth 1~2mm, feed rate 0.1~0.18mm/z, and Sialon ceramics have high toughness and are suitable for cutting solution treated Inconel 718 (HRC45) alloy. AI203-SiC whisker reinforced ceramics are suitable for machining nickel-based alloys with low hardness.

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Free-cutting aluminum alloys are widely used in the aerospace industry. Suitable tools include K10, K20, and PCD. The cutting speed is 2000~4000m/min, the feed rate is 3~12m/min, the tool rake angle is 12°~18°, the back angle is 10°~18°, and the blade inclination angle can reach 25°.

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Studies have shown that when cutting at high speed, as the cutting speed increases, the cutting force decreases, the cutting temperature rises very high, and the rise gradually slows down after reaching a certain value. The main cause of tool damage is wear and damage such as mechanical friction, bonding, chemical wear, chipping, crushing and plastic deformation under the action of cutting force and cutting temperature. Therefore, the most important requirements for high-speed cutting tool materials are mechanical properties, thermophysical properties, anti-bonding properties at high temperatures, chemical stability (oxidizability, diffusivity, solubility, etc.) and thermal shock resistance and coating crack resistance. Based on this requirement, a number of tool materials suitable for high-speed cutting have been developed in the past 20 years, which can cut various workpiece materials under different cutting conditions.

Specialty Tool & Mold Inc. is set up for and has processes in place to meet the quick demand of our customers. This allows us, to provide the highest quality tooling in the shortest amount of time possible.

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Titanium alloy has high strength and impact toughness, and its hardness is slightly lower than Inconel718, but its work hardening is very serious, so high temperature and severe tool wear occur during cutting. Experiments show that high-speed milling of titanium alloy with a 10mm diameter carbide K10 two-edge spiral milling cutter (helix angle of 30°) can achieve satisfactory tool life, cutting speed can be as high as 628m/min, and the feed per tooth can be 0.06~0.12mm/z. The cutting speed of continuous high-speed turning of titanium alloy should not exceed 200m/min.

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Inconel718 nickel-based alloy is a typical difficult-to-process material with high high-temperature strength, dynamic shear strength, and low thermal diffusion coefficient. It is easy to produce work hardening during cutting, which will lead to high temperature in the cutting area of ​​the tool and accelerated wear. When cutting this alloy at high speed, ceramic and CBN tools are mainly used. Silicon carbide whisker reinforced alumina ceramics can obtain longer tool life at 100~300m/min. When the cutting speed is higher than 500m/min, the tool wear of TiC-added alumina ceramics is small, while the notch wear is large at 100~300m/min.

The general trend of mechanical processing development is high efficiency, high precision, high flexibility and enhanced environmental awareness. In the field of mechanical processing, cutting (grinding) processing is the most widely used processing method. High-speed cutting is the development direction of cutting processing and has become the mainstream of cutting processing. It is an important common key technology of advanced manufacturing technology. The promotion and application of high-speed cutting technology will greatly improve production efficiency and processing quality and reduce costs. The development and application of high-speed cutting technology is determined by the progress of machine tools and tool technology, among which the progress of tool materials plays a decisive role.