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Carbide scarfing inserts are cutting tools made from carbide material that are designed for use in the scarfing process. Scarfing is a process used in the steel industry to remove the surface defects and oxides from steel billets, blooms, and slabs. The process involves cutting and removing the surface of the steel with a cutting tool.Carbide scarfing inserts are preferred for this process due to their high hardness and wear resistance. They are able to withstand the high temperatures and Carbide Inserts pressures involved in the scarfing process, and they can also achieve high cutting speeds and provide a smooth finish on the steel surface.Carbide scarfing inserts come in a variety of shapes and sizes, depending on the specific requirements of the scarfing process. They can be used in manual or automated scarfing operations, and are available in different grades and coatings to optimize their performance in different steel grades and cutting conditions.Related search keywords:carbide scarfing inserts, carbide insert, carbide inserts, carbide cutter, carbide inserts manufacturers, carbide inserts chart, carbide insert turning tools, carbide inserts Tungsten Steel Inserts for aluminum, carbide inserts for wood, carbide inserts suppliers, carbide inserts for sale, carbide insert angles, carbide insert aluminum, carbide insert rake angle, carbide insert boring bar, carbide insert blanks, carbide insert bits, carbide insert drill bits, carbide insert chip breakers, carbide insert for brass, carbide insert coatings
The Cemented Carbide Blog: tungsten carbide Inserts

Delcam, an Autodesk company, sets the industry standard for CAM software, and the company incorporates a wealth of new features into every release of its FeatureCAM product for automating CNC programming. FeatureCAM 2016 R3 delivers a wide range of new features and improvements such as new toolpath strategies and access to Autodesk A360 collaboration software.

The FeatureCAM 2016 R3 enhancements begin with the capability to automatically control rotational machine axes during indexing or 3+2 machining. Machine limits can be used from a machine design file, by specifying custom limits or using the shortest rotation the machine can take.

The new enhancements also include the ability to program two tools mounted to the same turning head toolholder. Turning heads are toolholders that enable turning operations when used on a WCMT Insert milling machine.

Next, FeatureCAM 2016 R3 users can now create spiral tool paths for face milling operations. Depending on the part shape, this can reduce air cutting for a more efficient toolpath.

The FeatureCAM 2016 R3 user interface improvements also enable an improved workflow. The improvements include a new apply button within the transform dialogue for faster transformations, quicker navigation to feature coolants from the results tab, a new feature tab for post-processor variables to improve navigation, and a change to the simulation algorithm that results in better simulation speeds.

Finally, the incorporation of Autodesk A360 enables project collaboration, file viewing and file sharing—all within a single, central workspace.

“FeatureCAM automates the workflow from design to NC code,” Coated Inserts says Sanjay Thakore, product marketing manager at Delcam. “Automation tools, including feature recognition, reduce programming time and increase programming consistency. The new features in FeatureCAM 2016 R3 will further enhance programming capabilities, ultimately resulting in increased productivity.”

Visit the company's IMTS showroom for more information.

The Cemented Carbide Blog: Milling Inserts

The saying “too many cooks spoil the broth” isn’t something that only applies to the culinary arts. It can also relate to manufacturing operations. At its Fountain Inn, South Carolina, plant, Bosch Rexroth was using multiple software suites for tool management, in turn causing communication challenges. By investing in the Tool Management Carbide Turning Inserts System (TMS) from Zoller (Ann Arbor, Michigan), the company was able to streamline its tool management system to a single suite to reduce quality issues and improve efficiency.

At its Fountain Inn plant, Bosch Rexroth produces many different axial piston hydraulic pumps and valve housings for its drive products used in heavy equipment and agricultural applications. The plant has two production buildings with more than 90 CNC machine tools—mostly DMG and Mori Seiki machining centers—operating 24/7. Iron and steel materials are received from foundry suppliers and machined on the four- and five-axis machining centers, which feature large tool storage capacities.

Due to the complex design of the products Bosch Rexroth manufactures, the machining centers make use of an expansive cutting tool inventory, which comprises mostly special designs that produce multiple diameters and other complex part features. These tools must be available immediately when needed. Also, it is essential for the company to keep accurate, timely track of engineering changes, item availability, tool regrinds over the tool inventory and other indirect materials used on the production floor.

Bosch Rexroth already had Zoller tool presetters in the plants to provide accurate tool offsets and avoid crashes and other manufacturing problems. However, the company was also using another software to run its engineering tool management. The Zoller software reported on the reality of the tools while the engineering software provided direction on how to make the tool. This was problematic because the toolsetter operators worked with one system and the engineers worked with another. It became a challenge to make sure they could communicate with each other.

The company’s Technical Functions (TEF) department decided it was necessary to streamline the tool management system to minimize tool and process cost, improve throughput and ensure consistently high part quality. Looking at all the Carbide Turning Inserts options, Bosch Rexroth decided to invest in the Zoller TMS, reducing what had been three software suites—design, inventory and measuring—to a single suite. Now, just one software manages the engineering, toolsetting and tool management, and only a single set of data is available to operators, tool setters and engineers. The Zoller TMS Silver package is a single suite of software that is designed to combine effective warehouse management and standardized production data management with organized tool management.

All information is managed by the single Zoller TMS database, yet tools can be managed from the office, CNC machines, Zoller Tool Organizers, vending machines and directly from the presetting and measuring machine. Since the system is modular, its functionality can be extended step by step going forward. Right now, Bosch Rexroth takes advantage of stored tool data and DIN4000 article characteristic information to optimize inventory cost control as well as tool production.

For the TEF department, the tool storage management module has been particularly useful, because it enables managing complete tool assemblies and components while keeping accessory inventories up to date. The storage location management in the warehouse includes a 3D design kit that enables current stock to be displayed three-dimensionally and items to be assigned to a virtual bin location. The database provides an overview of each item’s location, where it is in circulation, and the balance on hand in stores.

Feedback on circulation and stock levels are available at the push of a button. This is a major asset for increasing manufacturing transparency, which helps Bosch Rexroth run production economically around the clock when needed. The simple import and export of tool usage data also helps ensure quality and integration of various machines and departments.

There is no longer redundant data storage in multiple locations around the two production buildings—if an engineer makes a change to the tool design, it is visible to everyone. Previously, when the engineer made an update, that person would have to tell the tool setter to update his or her record as well, which took time and inevitably included some inaccuracy, says Dave Morley, Zoller product manager.

The company has started measuring every tool feature and adding tolerance information to the database, he says. Using the complete record, the engineer can now see the history of the tool’s setup measurement results. For example, the engineer can now know if the tool tolerance has been in the mid-range most of the time or if it has ever approached the limits. Without the complete record, this information would have been unavailable, making it difficult to meaningfully improve the tool design or features, Mr. Morley says.

Since engineers can now access the statistical measurement results for each tool assembly at a desk or the machine tool, they can make timely corrections or improvements to the tool design, which improves machining capacity, cycle times and part quality. It also helps identify and address the root cause of machining quality issues.

Bosch Rexroth has strict rules that a tool cannot be passed to manufacturing if it is out of tolerance; however, this has become less of an issue since engineers can now investigate any tool issues and look for a solution before cutting even starts. So far, tool breakage at Bosch Rexroth has been curbed from an average of 15 to fewer than eight tools per 1,000 parts produced.

The TEF department also wanted to better understand how the tools are used in the machines. The engineer can search the tool information through the TMS at a desk or at the presetters to make the connection between how the tool is set and how it performs. In terms of performance, this information is collected as the operator scans his or her badge, scans the machine identity and inputs the reason code for the tool change. It is now transparent which tools are changed the most and for what reasons.

The tool assembly history provided by the TMS is used to help optimize and control tool component inventory. Another way the tool management software controls inventory is through access to vending machines. At vending machines, users can look up the bill of material for any tool assembly and be accurately guided to the required components.

To keep designed tools organized, Bosch Rexroth uses the Zoller Tool Organizer to know the exact location of each and every tool or component. Flashing LEDs clearly indicate location of needed items, providing a fail-safe check-out system. Also, the Tool Organizer is interfaced directly to Zoller stock management.

As a result of Zoller’s TMS, the Bosch Rexroth plant has seen a reduction in quality issues and an increase in production efficiency. The TMS has also eliminated centers of “tribal knowledge,” meaning information no longer resides with just one or two people. Engineers are truly in charge of the tool. 

The Cemented Carbide Blog: Cemented Carbide Inserts

When a shop runs at full capacity, it must make efficiency High Feed Milling Insert gains any way possible. A few years ago, one such shop, Kennebec Tool & Die, embarked on a lean manufacturing program to eliminate waste and improve productivity. With 70 employees working in three shifts around the clock seven days a week, the Augusta, Maine-based company needed to standardize processes, equipment and tools in order to streamline its operations. One of the changes the shop made in order to meet its goals was to invest in a machining center equipped with through-spindle coolant.

However, the shop faced a persistent problem in its attempts to use the new machine and corresponding tooling for an important job—producing 700 assemblies per year for the semi-conductor industry. The shop was still on a learning curve for the new machine and tools, and cycle time issues on a particularly problematic component TNGG Insert of the seven-part assembly reduced productivity.

Made of 17-4 heat-treated stainless steel, the raw stock for the component arrives as a 4-inch-diameter bar that is cut to a rough length of 8.5 inches. After rough and finish turning, the component requires drilling of a 5-inch-deep internal bore with a tight tolerance. "Our turning operations were running pretty standard; it was really the drilling that was taking a long time," says Harvey Smith, vice president of operations.

Paul Owen, tooling room supervisor, says the source of the drilling operation’s lengthy cycle time could be traced to problems with consistent tool life. "Chips were wrapping around the drill, destroying the tool and/or scrapping the part," he explains. "We might get five parts from one insert and then six or eight from another."

Kennebec tried to work through the problem, but had to slow down the entire process in order to clean out the chips, further impacting productivity. The shop knew it needed to upgrade its drilling tools. However, in keeping with its lean manufacturing program, it sought to do so with the goal of not only addressing this specific application, but also reducing its total number of drill styles by finding a product that would work in a variety of situations. Soon, it had narrowed the vendors down to Seco Tools (Troy, Michigan) and a competitor.

To make a decision, Mr. Smith issued a challenge to Seco technical specialist Bryan Daniels: "If you can make this particular operation work, then I’m changing over to Seco."

Mr. Daniels delivered. He suggested a 1.187-inch-diameter, 5×D Perfomax indexable drill for the troublesome assembly component application. The Perfomax drill features two coolant holes and large chip flutes with a flute angle that is said to promote efficient coolant flow and effective removal of coolant and chips. This flute and the tool’s coated body and inserts are designed to allow high feeds and speeds while avoiding deflection, poor tool life and quality, even with long lengths and deep-hole drilling applications. Unlike many other indexable drills, the Perfomax can use two different insert grades. A tougher grade is located in the inboard position, while a more wear-resistant grade is mounted in the periphery pocket. Inserts are square to provide a strong 90-degree corner and the economy of four cutting edges.

"The operation was pretty much nailed as soon as we tried it," Mr. Owen says. "Bryan suggested the feeds and speeds, and we had no problems. He worked with us and optimized the parameters until we got a good average of parts per insert."

The drill ended up producing about 20 parts per edge—a threefold improvement in tool life compared with the shop’s previous drill. Additionally, the tool reduced cycle time from 1.21 to 0.53 seconds. While this might not seem significant, Mr. Smith explains that the actual cycle time savings are greater than the numbers show because the shop previously changed tools every five to eight parts. The drill’s longer tool life provided cost benefits, as well. While the Seco inserts cost more than competitive inserts, the increased tool life achieved with Perfomax actually reduced the comparative cost by $1.05 per produced part, Mr. Smith says.

Now, Kennebec uses Perfomax for almost all of its standard drilling applications. In fact, the drill has worked well enough to prompt the company to give Mr. Daniels a chance to prove Seco’s worth in other areas, including an 8,000-part aerospace order that requires a combination of turning and milling operations. "After (Mr. Daniels’) dedication on this last process and the success we achieved, we will certainly at least give Seco a try," Mr. Smith says.

The Cemented Carbide Blog: tungsten derby weights

K&H Industries has a long history of success as a tool and die shop and production metal stamper. In fact, the company has maintained steady production since the turn of the 20th century. Why would this company, which seemed to be running Carbide Aluminum Inserts just as it should, invest in a CNC machining center and draw manpower away from high-production stamping?

The answer to that question is twofold. First, machining capability streamlines tool and die production. Second, the new machining capability attracts new business from customers seeking critical, one-off parts.

Founded in 1905, K&H Industries differentiated itself by inventing new applications for stamping that solved practical problems. Examples include corner structures that made wooden milk crates stronger and easier to assemble, as well as electrical connections that are still in production today.

By the time Tom Sharkey purchased the company in 1997, it was still producing millions of parts per year. However, the new owner and his son, business manager David Sharkey, were not content to lean on previous Shoulder Milling Inserts success. More than twenty years later, David runs the shop floor with newfound efficiency, an achievement he credits to new processes and new technologies. When the opportunity arose to purchase a CNC machine tool, a Haas TM-2P, at auction in 2019, he saw the addition as a logical next step. 

On any given day, keeping stamping lines running might require everything from producing new parts to reproducing old parts to troubleshooting failed parts. Before, machining needs were split between in-house manual mills and a local EDM shop. The manual mills were so tedious, he recalls, that sending parts to the EDM shop was often faster, even if those parts didn’t require the precision of an EDM. With a CNC, David says he spends less time standing in front of the mill monitoring every pass. He can devote more attention to tasks like tending alarms, replacing stock on a stamping machine, shipping orders or communicating with customers.

As an example, he cites punches, which are common wear parts in stamping tooling. Featuring various angles and tapers, these parts require several tool changes. The CNC machine’s toolchanger performs this task automatically. Additionally, the part program can be re-used when the punch breaks again, rather than trying to recall the most efficient cutting strategies while also managing the shop.

Now, David says CNC has become a centerpiece of the shop’s productivity. Tom and David have settled into a rhythm where the initial design and customer consultation is completed by Tom in the front office, and then the part is programmed by David in BobCAD-CAM. The only parts that are still sent out to the EDM shop require tolerances tighter than +/- 0.001", such as die blocks and parts that interface with mating pins. 

Learning to use the CNC required David to spend months working through online tutorials and watching every video lesson he could, particularly Haas’s “Tip of the Day” series on YouTube. It wasn’t long before he wanted more, but not just for creature comforts. With a larger tool changer, a higher-capacity coolant system and a faster spindle for machining aluminum, the new Okuma Genos M560-V also helps with expanding business into one-off part replacements and emergency work for regular customers. 

In fact, the shop’s sole CNC machining center processes more emergency and one-off work for customers than in-house tooling, David says. Many of these customers do not have access to a CNC to make replacement parts for their own production lines, so providing this service helps build rapport. 

This is by design. The Sharkeys never run the machine at maximum capacity to ensure that it can handle rush orders without compromising other project timelines. This requires focusing on simple, competitive parts, David says, noting that the “sweet spot” includes those no larger than 4" x 10" x 24". 

As if to illustrate the point, one customer called while I was interviewing the Sharkeys, asking if a replacement part for a downed production line could be delivered the next day. David was happy to report that it would not be a problem. Running at full capacity may be the status quo somewhere else, but for the Sharkeys, keeping the machine open helps keep customers’ options open, too. 

The Cemented Carbide Blog: VCMT Insert

Zhuzhou Estool tools recently successfully participated in the METALLOOBRABOTKA exhibition, VNMG Insert which took place on May 22nd in Moscow, attracting industry experts and leaders from around the world.Metalloobrabotka is a Russian trade fair dedicated to the metalworking industry. It is one of the largest and most significant events in the field of machine tools, metalworking, and industrial equipment in Russia and the CIS countries. The event has been held annually since 1984 and attracts exhibitors and visitors from around the world.Metalloobrabotka showcases a wide range of products, technologies, and solutions Carbide Inserts related to metalworking and machine tools. The exhibition covers various sectors, including cutting and forming machine tools, automation and robotics, measurement and control systems, tooling, welding equipment, and much more. It provides a platform for manufacturers, suppliers, distributors, and industry professionals to showcase their products, network, and exchange knowledge.Related search keywords:carbide inserts,carbide inserts manufacturers,carbide inserts for stainless steel,carbide inserts suppliers,carbide inserts end mills,carbide inserts for wood,carbide inserts grade,carbide grooving inserts,carbide inserts holders,carbide inserts negative rake,negative rake carbide inserts,positive rake carbide inserts,zhuzhou carbide inserts,METALLOOBRABOTKA.
The Cemented Carbide Blog: cast iron Inserts

Allied Machine & Engineering (AME; Dover, Ohio), a manufacturer of holemaking and finishing tooling systems, has purchased Superion Inc. (Xenia, Ohio).

Superion has built its reputation as a manufacturer of special solid carbide and PCD-tipped rotary cutting tools such Carbide Drilling Inserts as end mills, reamers, drills and step tools.

“By acquiring Superion, Allied has added a wealth fast feed milling inserts of over 50 years of experience in special tool manufacturing,” says Bill Stokey, AME president and CEO. “Their highly-skilled associates operate CNC equipment and utilize sophisticated quality control systems to ensure the highest standards of quality.”

Customer sales and support will continue to be provided by both AME and Superion.

The Cemented Carbide Blog: parting tool Inserts

Tungaloy has expanded the multifunctional turning gravity turning inserts and boring capabilities of its TungBore-Mini line with boring toolholders that accommodate its unique XOMU inserts.

The company says its toolholders’ designs ensure secure ID machining processes. The design provides significant clearance between the tool and the hole surface to improve the evacuation of chips generated during boring or ID turning of small diameter bores.

Tungaloy’s angled screw fixation method employs an engaged screw that not only presses the insert against its primary bottom support, but also pulls the insert into the pocket wall. This design enables the use of a longer screw, providing strong insert retention and process security.

TungBore-Mini is a multifunctional drilling and turning Carbide Drilling Inserts tool line that integrates the capabilities of drilling, OD and ID turning tools. The geometry of its unique XOMU insert incorporates a large inclination angle on the cutting edge, producing lighter cutting than the standard ISO positive turning inserts typically used for ID turning or boring operations. TungBore-Mini’s insert and pocket also have a dovetail interlocking design that the company says provides better insert clamping and stability than standard screw-down insert clamping, enhancing process security during various applications.

Tungaloy has released eight variations of its boring toolholders for TungBore-Mini. These toolholders are available for minimum bore diameters of either 10 mm or 14 mm, with either a steel or a carbide shank.

The Cemented Carbide Blog: turning Inserts

1. The contradictory characteristics of traditional uniform carbideCemented carbide is a typical brittle material. The traditional uniform carbide one, the material of the various parts of the uniform composition and organization, the alloy is homogeneous throughout, its performance is consistent. The main components of cemented carbide include various hard phases and binding phases. Hard phases such as phases and solid solutions play an important role in the hardness and wear resistance of alloys. Bonding has an important influence on the strength and toughness of alloys.In general, increasing the WC grain size or increasing the Co content will increase the bond phase thickness of the alloy and improve the alloy plasticity. In alloys with good ductility, local concentrated stresses can relax the alloys with poor plasticity due to deformation. Crack initiation and propagation are induced by stress relaxation, resulting in cracking of the alloy.Therefore, the traditional method is to increase the alloy. The content and increasing the grain size serve as a direction to increase the toughness of the hard alloy. However, at the same time, the hardness and wear resistance are reduced. Conversely, hardness and wear resistance can be increased without sacrificing flexural strength and impact toughness. Therefore, there is a sharp contradiction between the hardness and toughness of cemented carbide materials, and it is not easy to obtain a conventional uniform cemented carbide with high hardness and toughness at the same time. In many service conditions, the application of traditional uniform hard alloys will have certain limitations. For example, when the rock drill ball and the cobalt head are working, they are not only subjected to impact load and torsional load, but also have to be seriously worn by the rock.This requires that the cobalt teeth not only have sufficient impact toughness, but also have high The wear resistance can complete its work. When used in synthetic diamond synthesis, carbide top hammers are subjected to high temperature and high pressure, some parts are subjected to compressive stress, and some parts are subjected to tensile stress or shear stress. Different parts have requirements.Different performance and features. In this way, the conflict between the hardness and toughness of the traditional uniform structure hard alloy restricts the further expansion of its application field, it is difficult to meet the "double high" high hardness and high toughness requirements for the development of modern society, so explore The new type of hard alloy material makes it particularly important that different parts of the tool have different functional requirements.2. New advances in cemented carbideThe materials scientists of various countries in the world are trying to solve the above-mentioned contradictions in the traditional uniform hard alloy through various effective ways, reduce production and use costs, and improve their comprehensive performance. At present, there are mainly ultra-fine and nano-hard alloys (so-called ultra-fine cemented carbide is an alloy with a tungsten carbide grain size of 0.2-0.5 μm, and nano-hard alloy is an alloy with a tungsten carbide grain size of less than 0.2 μm. ), platelet toughened carbide, coated carbide and functional gradient carbide, and other directions can effectively solve this contradiction. For example, when the cobalt content of the nano-size hard alloy is high, not only has good fracture performance, but also has a high hardness, reaching the best combination of alloy toughness and hardness functional gradient carbide by making the binder phase or hard phase along One direction is increasing or decreasing to give the different parts of the alloy different properties, so that the combination of toughness and wear resistance can be fully achieved in the use of the carbide. The following is a brief introduction to the new progress of gradient cemented carbide.Functionally Graded Cemented Carbide3. Gradient carbide proposedAbrupt changes in material composition and properties in the component often lead to significant local stress concentrations, whether the stress is internal or external. If the transition from one material to another is performed gradually, these stress concentrations will greatly increase. reduce.These considerations form the basic logical element of most functionally graded materials. Japanese scientists first proposed functionally graded materials, which are characterized by the introduction of gradual changes in the microstructure and/or composition of a component, the gradual change of its microstructure and/or composition in space, and the physical, chemical and mechanical properties of the material.The performance exhibits a corresponding gradient change in space, so that it meets different performance requirements at different locations in the component, thereby making the component as a whole achieve the best results.This design idea was introduced in the field of cemented carbide in the mid-to-late 1980s, and a gradient cemented carbide was proposed, and rapid development was quickly achieved. In the actual use of cemented carbide, different working sites often have different performance requirements. For example, the cemented carbide cobalt head requires high surface wear resistance and overall impact resistance.It is conceivable that if a new type of cemented carbide material can be developed, the structural feature of this material is that the surface layer is a structure with a low binder phase and the binder phase content of the core is an average value, between the surface layer and the core. It is a transition layer with a high binding content and a continuous distribution. In this kind of structure, due to the different distribution of bonding phase in each part, the content of the bonding layer in the alloy surface is lower than the average value in each part, with high hardness and good wear resistance, and the binding layer content in the transition layer. High, can meet good toughness and impact resistance.4. Properties of gradient cemented carbideIn the two-phase structure, the cobalt content of the surface layer is lower than the nominal cobalt content of the alloy, the cobalt content of the intermediate layer is higher than the nominal cobalt content of the alloy, and the cobalt content of the core containing the η phase is the nominal cobalt content of the alloy. As the cobalt content of the alloy shows a gradient change, the hardness of the different parts of the alloy also reflects the corresponding laws. Moreover, the gradient distribution of cobalt content makes the sintering shrinkage in different parts of the cross section non-uniform, resulting in residual stress in the alloy. Due to the low content of cobalt in the surface layer of the alloy and the high content of WC+Co+η, the surface of the alloy has very high hardness and very good wear resistance. In the middle layer of the alloy, the cobalt content is higher than the nominal content of the alloy, and thus The layer has good toughness and plasticity, so that the alloy can withstand higher loads. The η phase structure inside the alloy has good rigidity. The experimental results show that the wear resistance and toughness of DP alloy are obviously better than that of the traditional uniform hard alloy. The adoption of DP alloy can obviously improve the efficiency of rock drilling and reduce the mining cost.According to the current research status of gradient materials in various countries, there are mainly three types of gradient cemented carbide bonded phase composition carbides such as alloys, hard phase composition gradient cemented carbide (such as the β-layer used as a coating matrix. Gradient cemented carbide) and hard phase grain size gradient cemented carbide (such as grain-gradient cemented carbide top hammer).5. Gradient formation mechanismThe viewpoint of the formation mechanism of the gradient distribution of the cobalt phase caused by the directional migration of the liquid binder phase in the alloy after carburizing has not yet been unified. According to current research reports, the directional migration of liquid phase mainly includes mass migration caused by three different Carbide Milling Inserts types of liquid phases, orientational migration of binder phase caused by different WC particle sizes, and liquid phase migration caused by different carbon content. For example, two YG alloys with the same WC carbon content, uniform particle size, and different binder cobalt content are overlapped and held at the liquid phase temperature for a certain period of time. As a result, the bound cobalt phase shifts from a high cobalt content to a low cobalt content. One side of the migration,.For example, one of different particle sizes is fine particles, and the other is coarse particles added with the same cobalt to form two kinds of mixture, and pressed into a double-layer alloy for vacuum sintering. The liquid binding phase appears to be fine from one side to the other. The grain side migrates. While the high carbon cemented gravity turning inserts carbide is decarburized in the decarburizing atmosphere, the liquid binding phase will migrate from the inside to the surface of the sample, while the low carbon alloy will migrate to the center after the carburizing treatment liquid binding phase.The phenomenon of migration caused by the difference in carbon content is caused by the difference in the amount of liquid phase in the different parts of the alloy. This type of decarburized or carburized alloy has an unequal internal carbon content, and the carbon content is relatively high in regions with high carbon content. In regions with lower carbon content, the liquid phase migrates from areas with high carbon content to areas with low carbon content. Taken together, the main mechanisms of liquid phase migration are:The binder phase migrates from the coarse-grained carbide region to the fine-grained carbide region, and the driving force for the migration is the capillary pressure difference, that is, the action of the capillary force. The binding phase migrates from the high liquid phase region to the low liquid phase region and migrates. The driving force is the pressure difference in the liquid phase, that is, the role of volume expansion or contraction to generate pressure when the state of the substance in the liquid phase volume difference changes.6. Application of Gradient Cemented CarbideGradient cemented carbide successfully solves the contradiction between hardness and toughness existing in conventional homogeneous cemented carbide. The development of this new material is considered to be the most important one in the history of cemented carbide since the 1950s. Innovation." Due to the unique microstructure and properties of gradient cemented carbide, it has become an important research content in the field of gradient functional materials and hard alloys. Currently, it has been widely used in coating substrates, carbide cutting tools, mining and rock drilling tools, stretching dies and punching tools, and its application fields are constantly expanding.(1) Used as a coating substrateDue to the different thermal expansion coefficients of different materials, coating tool materials may crack due to thermal stress during cooling. Gradient structure cemented carbide is used as the matrix, that is, the gradient-sintered coating matrix forms a ductile region lacking cubic carbides and carbonitrides in the surface region, which can effectively prevent cracks formed in the coating from expanding into the interior of the alloy. , improve the interface bonding strength and reduce interface stress concentration, thereby improving the performance of carbide cutting tools.(2) Used as a carbide toolChange the traditional cemented carbide. The constant proportion model is used to make a graded structure hard alloy with low surface content and high core content, so that the surface layer has high hardness and good wear resistance, while the core has high strength and good impact toughness, which makes the strength and toughness of the alloy. It is well coordinated and can therefore be used to produce cutting tools with both wear resistance and toughness.(3) Mining and rock drilling tools Mining and rock drilling toolsThe use of ball teeth requires greater wear and impact during operation, which requires the alloy to have high surface wear resistance and high strength. Conventional uniform alloys are difficult to meet this requirement. Both wear resistance and toughness are significantly better than conventional uniform carbides.(4) Used as a punching toolSheet metal is usually prepared by punching or punching. With this method, the material is broken between working edges that face each other. During punching, the punch moves through the die in a direction perpendicular to the metal plate and punches the metal plate. The failure mode of the punch is usually due to the wear of the working edge and eventually leads to the cutting edge of the punch becoming conical, thereby increasing the frictional force during punching and eventually leading to a decrease in punching quality. In order to increase the life of the gradient carbide cutting tool as much as possible, a graded cemented carbide with a central η-phase region should be used, surrounded by a nucleus-free surrounding region, and with an exposed working surface of the η-phase. Using cemented carbide as the punch, the grain size of WC is 2-3μm, the number of punching times for standard cemented carbide is only 15 times, and the number of punching and shearing of cemented carbide for gradient structure is up to 64,000 times, while that of steel die punching The number is about 7231 times. It can be seen that gradient cemented carbide as a punching tool can greatly improve the service life of the tool.The study of gradient cemented carbide consists of three parts: material design, material preparation, and property evaluation. These three parts complement each other and are indispensable. Material preparation is the core of the gradient cemented carbide research. The material design provides the best composition and gradient distribution of the structure. To judge whether the designed and prepared material meets the predetermined function, performance evaluation must be performed.7. Gradient Cemented Carbide DesignGradient cemented carbide design, generally should go through the following several links First according to the structural shape of the components and the actual conditions of use, draw the thermodynamic boundary conditions from the existing material synthesis and performance database, select the possible synthesis of metal-ceramics Material combination system and preparation method Assume the combination ratio and distribution rule of the binder phase and the hard phase, and use the material microstructure mixing law to derive the equivalent physical parameters of the material structure using the thermoelastic theory and the calculation mathematics method. The distribution function of the gradient components of the material structure is simulated by temperature distribution and simulated by thermal stress, and the optimal composition distribution and material system are designed. The core work of gradient cemented carbide design consists of the following three parts:(1) Establish an appropriate gradient component distribution model so that the gradient functional material designed meets the performance requirements(2) Estimating physical properties of gradient materials(3) Calculation of temperature field and thermal stress of functionally graded materialsSee our tungsten carbide mining button bits here
Source: Meeyou Carbide

The Cemented Carbide Blog: Tungsten Carbide Inserts

What’s the standard tolerance of mold in CNC programming process?

The CNC programming department of the mold factory develops clear processing techniques and rod peeling inserts standards and performs standardized operations in the production process to improve work efficiency and reduce errors.
1.the former mold
a.Hot position
1 The size required for assembly must be based on the number.
2 Plane: The machining program is based on the number of dimensions, and the CNC operator measures the number according to the tolerance of the drawing size.
3 Side: The machining program is open for compensation. The unilateral side is left with a 0.02mm balance. The operator uses the needle gauge to fit tightly. The tolerance is guaranteed to be within 0.015~0.005mm. The other dimensions are based on the size of the 3D image.

b. Insert buckle
The side of the buckle of the insert shall be processed according to the shoulder milling cutters procedure, and the size shall be determined according to the size, and the depth (Z value) of the buckle of the insert shall be determined according to the number of dimensions, and the operator shall use the calibration gauge to measure the depth, and the tolerance requirement shall be 0.01 mm.

c.Glue size
The finishing procedure for all glue positions requires 0.02 mm on one side (except for special cases), and 0.15 mm on one side with fire pattern requirements for processing EDM lines.

d. Insert and touch the bit
Under normal circumstances, the front mold core is of a proper size, and the rear mold core retains the remaining amount.

e.Side lock position
The bottom depth (Z value) of the side lock position is made to be a standard size, and the side edge machining program of the side lock position needs to be compensated for one side to leave a 0.02 mm test fit. The operator is tightly matched according to the figure size, and the tolerance is guaranteed to be unilateral from 0.015 to 0.005 mm. Inside.

?2.the post mold

a.Row slot
The depth (Z value) of the row position slot shall be determined according to the number of drawings. The operator shall use the table to measure according to the tolerance of the drawing, and the two sides of the row groove shall be processed according to the drawing size. The program processing shall be compensated for one side and 0.02 mm. The test is equipped with the block gauge, and the tolerance is guaranteed within 0.015~0.005mm on one side.

b.Insert buckle
The side of the buckle of the insert shall be in accordance with the number of drawings, and the depth (Z value) of the bottom shall be in accordance with the number of dimensions. The operator shall use the calibration meter to measure the tolerance to a depth of 0.01 mm.

c.Mold hole position (hiding CORE bit)
The programmer does the light knife program and needs to open the compensation side to leave 0.02mm margin. The opening compensation operator measures according to the number of drawings. The single side is 0.005~0.01mm, which is convenient for assembly.

d. Glue size
All glue position finishing allowances are 0.02mm (except for special requirements).

e. Insert and touch the bit
Under normal circumstances, the rear mold needs to leave more than +0.02~0mm margin. The position of the rear mold with the row position must be determined according to the size of the row, and the position of the mold core after the matching of the row position needs more margin.

3.the mold convex CORE

a.When roughing, leave 0.5mm margin on one side, and when inserting the frame insert to the bottom to use rough machining CORE, leave 10mm at the bottom straight position for the operator to check if the roughing is loose and need to be quenched. The profiled convex CORE bottom is left straight for 10mm for finishing after quenching.

b.All glue positions are 0.02mm during finishing (except for special requirements), and the position to be inserted and penetrated is +0.02~0mm.

c.Convex CORE shape finishing, when the programmer makes the light knife program, the compensation is the 0.02mm margin on one side, and the operator can measure the tolerance of one side from 0~ –0.005mm according to the number of drawings.

d. The problem of the irregular shape of the mold insert (convex CORE) is detailed in the latter part.

4. row position, insert

a.When receiving the workpiece, the programmer should measure the external dimensions of the workpiece to avoid problems when the number of hits in the middle and the single side. The programmer needs to discuss with the operation group according to the shape of the workpiece, using a secure clamping method and a method of hitting the number. See the latter section for details.

b.The row position and the front and rear mold cores have matching positions, and the row position needs to leave 0.02 mm margin for FIT.

c. All glue positions are 0.02mm on one side (except for special requirements).

5. oblique top

According to the shape of the workpiece and the operation group, using a secure clamping method, the number of touches, all the glue positions are 0.02mm on one side (except for special requirements). Please add WeChat public number: industrial intelligence (robot info) Ma Yun are paying attention

6. mold processing

a.Mold
(1) The base word (chamfering) on the mold blank drawing should be consistent with the reference on the mold blank. In order to avoid misunderstanding, the machining chaos occurs, and the reference edge faces the direction of itself during programming.
(2) The machining positioning of all the templates establishes the machining coordinates by zeroing the guide hole in the near reference angle.
(3) Z-number hits definition: All templates are processed in forward and reverse directions. The number of touches at the bottom of the mold is zero. For workpieces with special requirements, the programmer needs to explain clearly with the relevant personnel and clearly indicate on the program list. The zero position of the mold embryo.

b.A board
(1) When the mold frame is finished, when the bottom of the mold frame is processed, the size must be made according to the size of the paper. The CNC operator uses the calibration of the drawing according to the tolerance of the drawing. The tolerance is +0.01~+0.02mm. The finishing process of the frame edge requires 0.02mm margin for the one side of the compensation. The operator fits the block gauge according to the size of the drawing. Tolerance Guaranteed 0.02 ~ 0.01mm on one side.
(2) The side lock position is made according to the bottom of the figure size. The side block gauge is tightly matched, and the tolerance is guaranteed within unilateral +0.015~-0.01mm.
(3) The bottom of the insert groove should be the number of quasi-sizes, and the side should be tightly tested with the block gauge. The tolerance is guaranteed within unilateral +0.015~ +0.01mm.
(4) The size of the shovel chicken trough and other dimensions are processed according to the plan.

c.B board

(1) Formwork finishing, the number of the standard size of the program processing frame is used, the CNC operator uses the table to measure according to the tolerance of the drawing, the tolerance is +0.01 0mm, the frame edge finishing, the program needs to open the compensation side 0.02mm The margin, the operator needs to use the block gauge according to the size of the figure, the tolerance guarantee – within 0.02~0.01mm on one side.
(2) The depth of the (Z value) at the bottom of the groove of the mold frame should be processed according to the drawing size. The operator uses the calibration meter according to the tolerance of the drawing. The tolerance is +0.01~+0.02mm, and the side program needs to open the compensation sheet. With a 0.02mm test fit, the operator needs to use the block gauge to tightly match the tolerance to unilateral +0.015~+0.01mm.

d Thimble panel:
(1) When the position of the ejector countersunk head is deep processing, the depth needs to be 0.02mm deep, and the operator uses the thousand points card to measure the tolerance, the tolerance is 0.02~0.01mm, and the side of the thimble countersunk head position needs to be processed to the size.
(2) The processing dimensions of the slanting top base assembly position are determined by the bottom of the ejector panel during the processing, and the operator uses the comparison table to measure the number while the side processing size is in place.
(3) The other positions are processed in accordance with the size of the 3D map.

e. thimble bottom plate:
(1) The size position required for the assembly of the insert, the operator needs to be tightly fitted with the block gauge, and the other positions are processed according to the size of the 3D drawing.
(2) C board: According to the 3D drawing size, the quasi-size is processed, and the working surface and the processing direction are selected by the boring machine group in the positive direction of the A code.
(3) Nameplate: It is required to be carved according to the requirements of 3D drawings.
(4) Upper fixing plate: The size of the mounting position is required for the assembly. The size of the upper fixing plate must be processed at the bottom of the upper fixing plate. The operator needs to use the meter to measure the number, while the side processing needs to open the compensation. 0.02mm, the operator needs to use the needle gauge to ensure that the single side is +0.015~+0.01mm, and other sizes are processed according to the 3D drawing.
(5) Lower fixing plate: There is the size required for the assembly of the insert. The bottom of the lower fixing plate needs to be processed to the quasi-size. The side is required to be tightly packed with the block gauge, and the other dimensions are processed according to the 3D drawing.

f.programming:

(1) Definition of steel processing coordinates: the rectangular reference is toward the person, and the square reference is toward the lower right corner. In a normal case, all the steel materials are programmed with X and Y points as 0, and the Z value is 0 at the bottom to establish the machining coordinates. (See CNC machining coordinate definition and clamping direction standard drawing 1, 2, 3)
(2)The roughing process is 0.5mm on one side, and the top of the mold is required to be quenched. It is easy to clamp during finishing.
(3) Finishing the bottom of the mold, avoiding the front of the mold, PL, glue position, etc.
(4) Mould tube position: The tube position programming of all front and rear mold cores is 0.01mm small.
(5) Planar PL processing: The program processing should be dimensioned according to the size of the drawing. The operator needs to use the calibration tolerance of the calibration meter to ensure that it is within +0.01~0mm.
(6)The arc surface PL processing, the programmer makes the test procedure, the program list indicates the smooth bottom plane PL, and the light knife processing program makes the standard size.

When the front and rear mold processing coordinates are defined, the rectangular reference is toward the person, and the square reference is toward the lower right corner (0 in the X and Y sides and the bottom is 0 in the Z), as shown in Figure 1, Figure 2, and Figure 3:

The convex CORE hit number is shown in Figure 4 and Figure 5;

The number of row seats is as shown in Figure 6:

The number of mold collisions is shown in Figure 7:

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