Is a carbide grooving insert suitable for applications with high-speed machining

Cermet inserts are cutting tools that are used in die and mold machining. They are becoming increasingly popular due to their ability to deliver high-quality machining results while being cost-effective and durable. Cermet inserts are composed of a ceramic material and a metal matrix, which makes them hard and resistant to wear. This makes them ideal for applications that require high heat and high pressure.

The major benefit of using cermet inserts in die and mold machining is their ability to deliver superior cutting performance. Cermet inserts have excellent cutting properties, allowing them to maintain their precise shape and size even after multiple uses. This means that the shape and size of the die or mold does not need to be changed after each use, saving time and money. In addition, cermet inserts are also capable of cutting a wide range of materials, including aluminum, stainless steel, and titanium.

Cermet inserts are also much harder than traditional cutting tools, which means they have a longer lifespan and require less frequent replacement. This, in turn, increases production efficiency and reduces downtime. Furthermore, cermet inserts are much more cost-effective than traditional cutting tools, making them a great option for cost-conscious manufacturers.

Finally, cermet inserts are also more environmentally friendly than traditional cutting tools. They produce less waste and require less energy to be produced, thus reducing the environmental impact of the machining process. Additionally, cermet inserts are also much more resistant to heat and friction, which helps to reduce the risk of sparks and fires.

In conclusion, cermet inserts are an excellent choice for die and mold machining. They offer superior cutting performance, a longer lifespan, lower costs, and a more environmentally friendly option. For these reasons, cermet inserts are becoming increasingly popular in the manufacturing industry.

Cermet inserts are cutting tools that are used in die and mold machining. They are becoming increasingly popular due to their ability to deliver high-quality machining results while being cost-effective and durable. Cermet inserts are composed of a ceramic material and a metal matrix, which makes them hard and resistant to wear. This makes them ideal for applications that require high heat and high pressure.

The major benefit of using cermet inserts in die and mold machining is their ability to deliver superior cutting performance. Cermet inserts have excellent cutting properties, allowing them to maintain their precise shape and size even after multiple uses. This means that the shape and size of the die or mold does not need to be changed after each use, saving time and money. In addition, cermet inserts are also capable of cutting a wide range of materials, including aluminum, stainless steel, and titanium.

Cermet inserts are also much harder than traditional cutting tools, which means they have a longer lifespan and TNMG Insert require less frequent replacement. This, in turn, increases production efficiency and reduces downtime. Furthermore, cermet inserts are much more cost-effective than traditional cutting tools, making them a great option for cost-conscious manufacturers.

Finally, cermet inserts are also more environmentally friendly than traditional cutting tools. They produce less waste and require less energy to be produced, thus reducing the environmental impact of the machining process. Additionally, cermet inserts are also much more resistant to heat and friction, which helps to reduce the risk Coated Inserts of sparks and fires.

In conclusion, cermet inserts are an excellent choice for die and mold machining. They offer superior cutting performance, a longer lifespan, lower costs, and a more environmentally friendly option. For these reasons, cermet inserts are becoming increasingly popular in the manufacturing industry.

How Can Inserts Improve Tool Life in Metal Cutting Operations

Carbide inserts have become a staple of machining operations in recent years, offering unbeatable performance for high-precision and high-speed operations. The versatility of carbide inserts makes them ideal for machining complex contours, allowing them to be applied to Carbide Inserts a variety of materials with superior results.

The ability of carbide inserts to cut complex contours is due to their unique design. Carbide inserts are composed of a metal substrate with a hard carbide coating, which provides a hard cutting edge for machining operations. This hard cutting edge allows for high-precision and high-speed cutting, making them ideal for machining complex contours. The carbide coating also adds a layer of protection, reducing the chances of burrs or chips, which can lead to defects in the finished product.

Carbide inserts also offer superior wear resistance, allowing them to be reused multiple times without sacrificing performance. As a result, they are an economical choice for machining complex contours. They also provide a longer service life, reducing the need for frequent replacements and resulting Surface Milling Inserts in a lower overall cost of ownership.

The versatility of carbide inserts makes them ideal for a variety of machining operations, from small-scale production runs to larger industrial-scale production. They are well-suited for a variety of materials, including aluminum, plastic, steel, and titanium. They can also be used for both wet and dry machining, making them a versatile option for a wide range of machining applications.

The high-precision and high-speed cutting capabilities of carbide inserts make them the perfect choice for machining complex contours. Their versatility and durability make them an economical choice for a variety of machining operations. With their ability to reduce the chances of burrs and chips, carbide inserts are redefining the limits of machining complex contours.

How to Select the Right Indexable Inserts for Your Machining Needs

Ceramic CNC inserts are becoming an increasingly popular choice for machining operations due to their superior performance and cost savings. As the name implies, ceramic CNC inserts are made from a ceramic material that can withstand high temperatures and provide a very sharp cutting edge that is ideal for machining projects. Ceramic CNC inserts are engineered to last longer and provide superior performance compared to traditional carbide inserts.

The main benefit of ceramic CNC inserts is their superior cutting performance. Ceramic CNC inserts can provide a higher feed rate, better surface finish, and longer tool life DNMG Insert than traditional carbide inserts. This makes them an ideal choice for high-volume production operations. Additionally, ceramic CNC inserts are highly heat resistant, making them ideal for cutting operations that generate a lot of heat. This means that they can handle higher cutting speeds without risk of thermal damage.

Ceramic CNC inserts are also much more cost-effective than traditional carbide inserts. They are typically more affordable, making them a great option for businesses that need to stay within budget. Additionally, ceramic CNC inserts require less maintenance and can last much longer than carbide inserts. This further reduces the cost of machining operations and increases overall productivity.

Overall, ceramic CNC inserts are an excellent choice for machining operations. They offer superior cutting performance, better surface finish, longer tool life, and significant cost savings. With all these benefits, tungsten carbide inserts ceramic CNC inserts are an ideal choice for businesses looking to boost their machining performance.

Carbide Inserts for Shipbuilding： Precision and Durability in Marine Construction

Carbide inserts are one of the most versatile and efficient cutting tools for machining a variety of materials. They are used for high-speed machining of many metals including steel, aluminum, brass, and even zinc. Zinc is a difficult material to machine due to its low strength and propensity to wear out cutting tools. However, with the right tooling and cutting parameters, carbide inserts can provide a solution to the challenge of machining zinc efficiently.

The most important factor when machining zinc with carbide inserts is the choice of insert grade. It is important to select an insert grade that is designed for machining TCGT Insert zinc. This ensures that the insert will be able to handle the heat and stress generated from high-speed machining of the zinc. The grade should also provide good edge strength and wear resistance so it can maintain its cutting edge over a long period of time.

Once the correct insert grade has been chosen, the next step is to select the best cutting parameters for machining zinc. The depth of cut and cutting speed should be adjusted to provide the best balance between cutting efficiency and tool life. Too much depth of cut or too high of a cutting speed can lead to premature tool wear and reduced tool life.

The use of coolant when machining zinc is also important. The coolant helps to dissipate heat generated during the cutting process and also helps to lubricate the cutting edge, which helps to reduce tool wear.

Overall, carbide APKT Insert inserts provide an effective and efficient solution to the challenge of high-speed machining of zinc. The correct selection of insert grade and cutting parameters will ensure that the tool can handle the heat and stress generated during the process and will maintain its cutting edge over a long period of time. In addition, the use of coolant during the machining process can help to reduce tool wear and maximize the life of the insert. With the right tooling and cutting parameters, carbide inserts can unlock the potential for high speed machining of zinc.

The Advantages of Using Threading Cutting Inserts

Titanium machining is a specialized process that requires careful consideration of many factors in order to achieve the desired results. Inserts for machining titanium are an important part of the process, and there are several key considerations for choosing the right inserts for the job.

First, the type of insert must be chosen based on the type of material being machined. This will determine the hardness and toughness of the insert, and the best type for titanium machining will depend on the application. For example, if the goal is to machine a flat surface, then a harder insert is usually best.

Second, the cutting edge of the insert should be chosen based on the required cutting speed and depth. A sharp edge is necessary for fast and effective cutting, while a dull edge will lead to longer cutting times and poor surface finish. Different types of inserts can be used for different cutting speeds and depths.

Third, the material of the insert should be chosen based on the type of titanium being machined. A harder material is usually best for harder grades of titanium, while softer materials may be better for softer grades.

Finally, the shape of the insert should be chosen based on the type of machining being done. If the goal is to make round holes, then a round insert is usually best. If the goal is to machine a complex shape, then a more complex insert may be needed.

Choosing the right inserts for titanium machining is an important part of the process. Careful consideration of the type, cutting edge, material, and shape of the insert is necessary in order to achieve the desired results.

Titanium machining is a specialized process that requires careful consideration of many factors in order to achieve the desired results. Inserts for machining titanium are an important BLMP Inserts part of the process, and there are several key considerations for choosing the right inserts for the job.

First, the type of insert must be chosen based on the type of material being machined. This will determine the hardness and toughness of the insert, and the best type for titanium machining will depend on the application. For example, if the goal is to machine a flat surface, then a harder insert is usually best.

Second, the cutting edge of the insert should be chosen based on the required cutting speed and depth. A sharp edge is necessary for fast and effective cutting, while a dull edge will lead to longer cutting times and poor surface finish. Different types of inserts can be used for different cutting speeds and depths.

Third, the material of the insert should be chosen based on the type of titanium being machined. A harder material is usually best for harder grades of titanium, while softer materials may be better for softer grades.

Finally, the shape of the insert should be chosen based on the type of machining being done. If the goal is to make round holes, then a round insert is usually best. If the goal is to machine a complex shape, then WCKT Inserts a more complex insert may be needed.

Choosing the right inserts for titanium machining is an important part of the process. Careful consideration of the type, cutting edge, material, and shape of the insert is necessary in order to achieve the desired results.

Metal Plating Process： Understanding Its Types and Techniques_2

Hard turning is a complex and precise machining process used to machine precision inserts in hardened material. Most commonly, these inserts are used to hold screws, nuts, and bolts in place. However, hard turning can also be used to machine other components such as bearings and gears. In order to achieve the highest quality precision insert, there are several key considerations that must be taken into account when machining these inserts.

The first key consideration for machining inserts in hard turning is the material of the inserts. Hardened material is much more difficult to machine than softer materials, so the insert material must be chosen carefully. Additionally, the hardness of the material must be taken into account, as this will determine the cutting tools and methods required.

Another key consideration is the cutting tools that are used for the machining process. Different materials require different cutting tools, and it is important to choose the right tools for the job. In general, the harder the material, the stronger and more resilient the cutting tool must be.

Finally, the cutting parameters must be carefully chosen. This includes the speed and feed rate of the cutting tool, as well as the depth of cut and the type of cutting fluid used. It is important to choose the optimal parameters for each individual job to ensure that the best results are achieved.

Keeping these key considerations in mind when machining inserts in hard turning is essential to achieve the best possible results. By choosing the right material, cutting tools, and cutting parameters, precision inserts can be machined with greater accuracy and reliability.

Hard turning is a complex and precise machining process used to machine precision inserts SPMG Inserts in hardened material. Most commonly, these inserts are used to hold screws, nuts, and bolts in place. However, hard turning can also be used to machine other components such as bearings and gears. In order to achieve the highest quality precision insert, there are several key considerations that must be taken into account when machining these inserts.

The first key consideration for machining inserts in hard turning is CNMG Cermet Inserts the material of the inserts. Hardened material is much more difficult to machine than softer materials, so the insert material must be chosen carefully. Additionally, the hardness of the material must be taken into account, as this will determine the cutting tools and methods required.

Another key consideration is the cutting tools that are used for the machining process. Different materials require different cutting tools, and it is important to choose the right tools for the job. In general, the harder the material, the stronger and more resilient the cutting tool must be.

Finally, the cutting parameters must be carefully chosen. This includes the speed and feed rate of the cutting tool, as well as the depth of cut and the type of cutting fluid used. It is important to choose the optimal parameters for each individual job to ensure that the best results are achieved.

Keeping these key considerations in mind when machining inserts in hard turning is essential to achieve the best possible results. By choosing the right material, cutting tools, and cutting parameters, precision inserts can be machined with greater accuracy and reliability.

Sandvik Coromant GC1020 And GC3220 Milling Tools

The true art of engineering is seen in complex mechanical assemblies. Cemented Carbide Inserts Take a look inside a wristwatch; the perfect harmony in which all the tiny components work together is nothing less than mesmerizing. This is a prime example of engineering fits, which are the topic of this discussion.

In this article, we will talk about the different types of fits, their standards, applications, and some common techniques to create them. Let’s get started!

What is an Engineering Fit?

Engineering fits are a kind of mechanical assembly where two mating parts are joined together, either permanently or temporarily. The word ‘fit’ characterizes the amount of mechanical clearance, or the extent of physical contact, between the mating components.

If the parts are fit together tightly and the joint can carry loads, it is an interference Coated Inserts fit. On the other hand, a transition fit characterizes a joint that carries sufficient force to maintain contact but cannot withstand high loads. The third category, clearance fit, has a small gap between the mating components, allowing free rotation or sliding between them.

Basis of Fits: Hole and Shaft System

The hole and shaft basis system is a popular standard for engineering fits. It has two variants: hole-basis or shaft-basis systems. For both, the base component has fixed dimensions while the other component is sized to achieve the fit. For example, in the shaft-basis system, the shaft diameter is fixed and the hole diameter is adjusted.

Of these two, the hole-basis system is by far the most popular as it is more convenient to control the diameter of shafts compared to holes.

The shaft-basis system is not completely disregarded though. When sizing the shaft is infeasible, for instance with a high-speed rotating shaft after mass balancing, the hole size is altered to achieve the fit.

Types of Fits

As we briefly mentioned before, there are three main categories of engineering fits. Each one has a different mechanical contact and a different job to perform. In this section, we dive deep into these types of fits and their sub-categories.

1. Interference Fit

The interference fit is a type of engineering fit where high frictional force tightly holds the mating surfaces together. Consequently, the interference fit is also known as a friction fit.

The tightness of interference fits comes from its negative clearance. This means that the mating surfaces press into each other. In other words, the mating surfaces deform inwards under contact pressure. For instance, in a hole and shaft system, the hole is actually smaller than the shaft in an interference fit. The shaft is forcefully press-fit (another name for interference fit) into the hole via a hydraulic press or hammers.

Additionally, another common method to create interference fits is by shrink-fitting. In this technique, one of the parts is either cooled or heated so that it contracts or expands (respectively) enough for the negative clearance to momentarily change to positive clearance. After locating the parts against each other, the temperatures normalize. The resulting thermal shrinkage/expansion creates a tight interference fit.

Generally, the clearance in an interference fit is -0.001mm to -0.042mm. Now, let’s see the sub-categories of interference fit:

Press Fit: A lighter variant of press fitting with minimal negative clearance for medium-strength joints.

Driving Fit: Medium interference joint that can carry loads and requires cold/hot pressing and force to assemble.

Forced Fit: Forced fits are the strongest type of engineering fit. They require cold/hot pressing and are almost always permanent. Their assembly warrants careful tolerancing and placement to avoid the breakage of parts.

2. Clearance Fit

A clearance fit has a positive allowance. This means that there is a slight gap between the mating surfaces. As a result, the parts also have some play, but it is negligible and often not observable to the naked eye.

Due to this play, parts in a clearance fit have a certain degree of freedom (of movement). For example, the pin and frame in pivot joints have a clearance fit, allowing both components to move independently of each other but also stay locked in place at the same time.

The common range of clearance in these engineering fits is +0.025mm to +0.089mm. A summary of the clearance fit types is as below:

Loose Running: The clearance is set at the higher end of the range given above. Parts in a loose running clearance fit are free to rotate/slide and have an observable play.

Free Running: Similar to a loose running joint. Parts can move at high speeds and the joint can accommodate thermal expansion. However, the location accuracy is low due to considerable play.

Close Running: Close running fits have a slightly better positioning accuracy and allow parts to move even at high temperatures and speeds.

Sliding: Sliding joints are high-accuracy engineering fits. Clearance is kept to a minimum to restrict all degrees of freedom except in the sliding direction.

Location: Location fits are very high-precision fits to locate the mating parts accurately. The clearance is very low and requires lubrication to allow smooth motion.

3. Transition Fit

Transition fit is a middle ground between the other two engineering fits. Depending on the application, the mating parts can have either a small interference or clearance.

If there is a negative interference, like an interference fit, the pressure and load-carrying capacity is not that high. If there is a clearance, as with a clearance fit, there is not as much play.

Typically, a transition fit is useful for precision-locating parts in assembly operations. It restricts their relative movements while also preventing extreme mechanical stresses.

The mechanical interference/clearance in transition fit ranges between +0.023mm to -0.018mm. Furthermore, transition fit has two common types:

Similar Fit: A very light engineering fit with near-zero clearance/interference. Generally, a human-applied force with a mallet is sufficient to achieve the fit.

Fixed Fit: Slightly tighter than a similar fit that requires a press to achieve.

Engineering Fits: The Big Picture

The information in the previous section can be too much to absorb in one go. To understand it better, let us zoom out a bit and try to get a bird’s eye view of engineering fits. A great way to do this is to discuss common engineering standards for types of fits.

The two most popular standards regarding engineering fits are ISO 286 and ANSI B14.1. Both standards provide comprehensive information on tolerance ranges for different fit types. One can find reference tables from these standards in every fabrication shop, signifying their importance in the industry.

Since the ISO standard is the more well-known of the two, the following chart focuses on it.

Type of Fit	Hole Basis	Shaft Basis	Fit Type	Applications
Clearance Fit	H11/c11	C11/h11	Loose Running Fit	Pivots, parts with corrosion and dust, parts exposed to thermal changes
	H9/d9	D9/h9	Free Running Fit	Cylinder-piston assemblies, slow-rotating parts
	H8/f7	F8/h7	Close Running Fit	Machine tool spindles, shaft bearings, sliding joints
	H7/g6	G7/h6	Sliding Fit	Sliding gears, clutch disks, hydraulic pistons
	H7/h6	H7/h6	Locational Clearance Fit	Machine tool guides, roller guide rails
Transition Fit	H7/k6	K7/h6	Locational Transition Fit	Wheels, brake disks, gears/pulleys on shafts
	H7/n6	N7/h6	Locational Transition Fit	Motor armature windings, gears
Interference Fit	H7/p6	P7/h6	Locational Interference Fit	Hubs, clutches, bushings for bearings
	H7/s6	S7/h6	Medium Drive Fit	Permanent gear/pulley assemblies, bearing mounting
	H7/u6	U7/h6	Force Fit	Flange mounting, gears, shafts

How to Achieve Dimensional Tolerances for Fits?

It is clear from the above discussion that dimensional tolerance is a critical factor for accurate engineering fits. However, manufacturing the mating parts within the required dimensional tolerances is a skillful task.

Generally, the tolerance limits are included in engineering drawings via appropriate GD&T symbols. GD&T sets acceptable limits on the amount and nature of geometric deviations from the true geometry. Thus, the fabricator must manufacture the parts within these set limits.

There are numerous techniques manufacturers may utilize to achieve this. These include:

CNC Precision Machining: CNC machines have remarkable accuracies up to +/- 0.001mm. Using the correct tooling and fixturing, machinists can produce accurate parts for engineering fits.

Grinding: Grinding is the go-to method for ultra-precise manufacturing owing to its impressive manufacturing accuracy of +/- 0.25 microns. For critical applications like a forced interference fit, tolerances of this order are common.

Reaming: It is a specialized application for hole-making. Since holes are a very common mating component in engineering fits, reaming is worth a mention in this list. Since it is a precise method that removes a minuscule amount of material, it is useful in bringing holes within the tight dimensional tolerances required for mechanical fits.

Conclusion

Engineering fits are indispensable for the manufacturing industry. We would not have assembled products without them! The three fit types: interference fit, transition fit, and clearance fit, all play essential roles in various products like shafts (gears, pulleys, and bearings), machine tool slides, clutches, etc. Therefore, it is great to be knowledgeable about this topic as a technical professional.

WayKen is an ISO-certified rapid prototyping company. Our diverse range of services includes precision machining, 3D printing, and rapid tooling, where we take special care to achieve the right types of fits for your specific applications. Feel free to contact us for your projects.

FAQs

What are the fits and tolerances?

Fits, or mechanical/engineering fits, are a type of mechanical joint where two parts are assembled together with some clearance between their mating surfaces. The clearance can be positive or negative based on the type of mechanical fit. Tolerances are the dimensional limits within which these parts must be produced in order to achieve the correct type of fit.

How to choose a fit for my application?

The choice of engineering fit depends upon several factors. The amount of movement or load-carrying capacity of the joint is the first consideration. Other important factors include the quality and strength of components being assembled, part geometry, manufacturing capability, and fabrication costs.

How to calculate engineering fit tolerance?

Engineering fit tolerances can be selected using guidelines from well-known engineering standards like ISO or ASME. One can find detailed information on engineering dimensions and tolerances for each type of fit and hole/shaft size.

What is ATC(Auto Tool Changer)？

Metal forming is the shaping of metal parts and objects by mechanical deformation, applying stresses to give them the desired shape. Today we will take a look at the 8 types of metal forming processes: casting, plastic forming, machining, welding, powder metallurgy, metal injection molding, metal semi-solid forming, and 3D printing. Contents hide 1Casting 1.1Process flow 1.2Process features. 2Plastic forming 2.1Forging 2.1.1Technical characteristics. 2.1.2Applications. 2.2Rolling 2.2.1Rolling classification. 2.2.2Applications 2.3Extrusion 2.3.1Process flow 2.3.2Advantages 2.3.3Disadvantages 2.4Drawing 2.4.1Advantages 2.4.2Disadvantages 2.5Stamping 2.5.1Technical characteristics. 2.5.2Scope of application. 3Machining 4Welding 5Powder metallurgy 5.1Advantages. 5.2Disadvantages. 5.3Production range of application. 6Metal Injection Molding 6.1MIM process flow 6.2Technical features. 6.3Technology core. 7Semi-Solid Metal Molding 7.1Technology features. 7.2Applications. 83D PrintingCasting

Liquid metal is poured into the cavity of the casting mold that is compatible with the shape and size of the part and left to cool and solidify to obtain a blank or part of the production method, usually called liquid metal forming or casting.

Process flow

liquid metal → filling → solidification and shrinkage → casting

Process features.

1) It can produce parts with arbitrarily complex shapes, especially those with complex internal cavity shapes.
2) High adaptability, no restriction on alloy types and almost no restriction on casting size.
3）Wide source of materials, scrap can be remelted, low investment in equipment.
4）High scrap rate due to cracks, low surface quality and poor labor conditions.

Plastic forming

Plastic forming: It is the process of using the plasticity of the material to process the parts with less cutting or no cutting under the action of external force of tools and dies. It has many types, mainly including forging, rolling, extrusion, drawing, stamping, etc.

Forging

Forging is a processing method that uses forging machinery to apply pressure to metal billets to produce plastic deformation in order to obtain forgings with certain mechanical properties, certain shapes and sizes.

According to the forming mechanism, forging can be divided into free forging, die forging, lapping ring, special forging.

Free forging: Generally, it is the processing method to hammer the metal ingots or blocks into the required shape and size by using simple tools on the hammer forging or water press.

Die forging: It is formed by using dies on a die forging hammer or hot die forging press.

Ring lapping: refers to the production of ring-shaped parts of different diameters by special equipment ring lapping machine, also used to produce wheel-shaped parts such as automobile wheels and train wheels.

Special forging: including roll forging, wedge cross-rolling, radial forging, liquid die forging and other forging methods, these methods are more suitable for the production of certain special-shaped parts.

Process flow: forging billet heating → roll forging preparation → die forging forming → edge cutting → punching → correction → intermediate inspection → forging heat treatment → cleaning → correction → inspection

Technical characteristics.

(1) the quality of forgings than castings can withstand the effects of large impact, plasticity, toughness and other aspects of mechanical properties are also higher than castings or even higher than the rolled parts.
(2) save raw materials, but also shorten the processing time.
3) High production efficiency example.
4) Free forging is suitable for single-piece small batch production and is more flexible.

Applications.

Rollers and herringbone gears of large steel rolling mills, rotors, impellers and guard rings of turbine generator sets, working cylinders and columns of huge hydraulic presses, locomotive axles, crankshafts and connecting rods of automobiles and tractors, etc.

Rolling

Differing from forging, rolling makes the metal billet through the gap between a pair of rotating rolls (various shapes), due to the compression of the rolls forming rolling to reduce the material cross-section, the length of the pressure processing method increases.

Rolling classification.

According to the movement of rolling parts are: longitudinal rolling, horizontal rolling, oblique rolling. Longitudinal rolling: is the metal in two rotational direction between the rolls through, and the process of plastic deformation in between.Cross-rolling: rolling deformation after the direction of movement and roll axis direction.Oblique rolling: rolled parts for spiral movement, rolled parts and roll axis non-special angle.

Applications

Mainly used in metal material profiles, plates, tubes, etc., and some non-metal materials such as plastic products and glass products.

Extrusion

Extrusion: The billet is extruded from the orifice or gap of the die under the action of uneven compressive stress in three directions so that the cross-sectional area is reduced and the length is increased to become the desired product processing method called extrusion, and this processing of the billet is called extrusion molding. 330mm long carbide rods are typical products made by using extrusion.

Process flow

Pre-extrusion preparation → casting bar heating → extrusion → stretching twisting straightening → sawing (sizing) → sampling inspection → artificial aging → packaging into storage

Advantages

1) Wide range of production, many product specifications and varieties.
2) High production flexibility, suitable for small batch production.
3) High dimensional accuracy and good surface quality of products.
4) Low investment in equipment, small plant area, easy to realize automatic production.

Disadvantages

1) large geometric waste loss.
2) Uneven metal flow.
3) low extrusion speed and long auxiliary time.
4) High tool loss and high cost.

Production scope of application: mainly used for manufacturing long rod, deep hole, thin wall, shaped section parts.

Drawing

Drawing: A plastic processing method in which a metal billet is pulled out from a die hole smaller than the billet section with an external force acting on the front end of the drawn metal to obtain a product of the corresponding shape and size.

Advantages

1) Accurate size and surface finish.
2) simple tools and equipment.
3) Continuous high-speed production of long products with small cross-sections.

Disadvantages

1) limited amount of deformation between passes and total deformation between annealing.
2）Length is limited.

Production range of application: drawing is the main processing method for metal pipes, bars, profiles and wires.

Stamping

Stamping: It is a forming process that relies on presses and dies to apply external forces to plates, strips, pipes and profiles to produce plastic deformation or separation to obtain workpieces (stampings) of the desired shape and size.

Technical characteristics.

1) Light weight and high rigidity products can be obtained.
(2) Good productivity, suitable for mass production and low cost.
(3) Uniform quality of products can be obtained.
(4) High material utilization, good shearability and recyclability.

Scope of application.

60-70% of the world’s steel WCMT Insert is plate, most of which is made into finished products after stamping. The body, chassis, fuel tank and radiator sheet of automobile, steam ladle of boiler, shell of container, silicon steel sheet of iron core of motor and electric appliance are all stamping processed. There are also a large number of stamping parts in products such as instruments, household appliances, bicycles, office machinery, and living utensils.

Machining

Machining: is in the parts production process, directly with the tool in the blank to remove the excess metal layer thickness, so that it or the drawings required by the size accuracy, shape and location of mutual accuracy, surface quality, and other technical requirements of the processing process.

Commonly used machining methods are 1. Turning · 2. Drilling · 3. Milling · 4. Grinding · CCMT Insert 5. Planing · 6. Sawing · 7. Broaching · 8. Electric Discharge Machining.

Welding

Also known as fusion welding, fusion welding is a manufacturing process and technique for joining metals or other thermoplastic materials such as plastics by means of heat, high temperature or pressure.

Powder metallurgy

It is the process technology to make metal or use metal powder (or mixture of metal powder and non-metal powder) as raw material, through forming and sintering, to manufacture metal materials, composite materials and various types of products. And tungsten carbide is made using this technology.

Advantages.

1) Most refractory metals and their compounds, pseudo-alloys, and porous materials can only be manufactured by powder metallurgy methods.
2) Save metal and reduce the cost of products.
3）Does not give the material any pollution, it is possible to make high purity material.
4）Powder metallurgy method can ensure the correctness and uniformity of material composition ratio.
5）Powder metallurgy is suitable for producing the same shape and a large number of products, which can greatly reduce the production cost.

Disadvantages.

1) In the absence of batch size to consider the size of the part.
2) The cost of the mold is relatively higher than the casting mold.

Production range of application.

Powder metallurgy technology can be directly made into porous, semi-dense or fully dense materials and products, such as oil-containing bearings, gears, cams, guide rods, tools, etc.

Metal Injection Molding

MIM (Metal injection Molding ): It is the abbreviation of metal injection molding. It is a molding method in which a plasticized mixture of metal powder and a binder is injected into a model. It is to mix the selected powder with the binder first, then granulate the mixture and inject it into the desired shape.

MIM process flow

The MIM process is divided into four unique processing steps (mixing, molding, degreasing and sintering) to achieve the production of parts, and the need for surface treatment is determined by the product characteristics.

Technical features.

1) Forming responsible parts in one go.
2) Good surface quality of the manufactured part, low scrap rate, high production efficiency and easy automation.
3) Low requirements for mold materials.

Technology core.

Bonding agent is the core of MIM technology Only by adding a certain amount of bonding agent, the powder has enhanced fluidity to be suitable for injection molding and maintain the basic shape of the blanks.

Semi-Solid Metal Molding

Semi-Solid Molding: The unique rheology and churning properties of non-dendritic semi-solid metals (SSM) are used to control the quality of the casting. Semi-solid molding can be divided into rheological molding and thixotropic molding.

Technology features.

1) Reduction of liquid molding defects and significant improvement in quality and reliability.
2) lower molding temperature than all-liquid molding, which greatly reduces the thermal shock to the mold.
3) The ability to make alloys that are impossible to make by conventional liquid forming methods.

Applications.

It has been successfully used in the manufacture of master cylinders, steering system parts, rocker arms, engine pistons, wheel hubs, transmission system parts, fuel system parts and air conditioning parts, etc. in aviation, electronics as well as consumer products.

3D Printing

3D printing: A type of rapid prototyping technology, it is a technology that constructs objects by printing layer by layer using bondable materials such as powdered metal or plastic, based on digital model files.

The Evolution Of Cemented Carbide

Molybdenum is the most widely used materials in the processing industry. It can be used in the iron and steel industry, most of which are industrial molybdenum oxide briquette directly used for steelmaking or cast iron, a small part is smelted into ferromolybdenum and then used in steelmaking, or synthesized with other metals to make molybdenum plates.

Plates made of molybdenum or molybdenum alloy can improve the corrosion resistance, strength and wear resistance of the original metal. With the characteristics of high melting point, low density and small thermal expansion coefficient, they are also used as an excellent catalyst and lubricant. Molybdenum disulfide plate also has unique anti-sulfur properties, and it is a promising C1 Carbide Drilling Inserts chemical catalyst under certain conditions to catalyze the hydrogenation of carbon monoxide to produce alcohols.

Molybdenum plates have the potential to replace graphene in the electronics industry. Transistors made of molybdenum consume 1/100,000th of the power consumption of silicon transistors in standby conditions and are cheaper than graphene circuits of the same size. However, the biggest change is Its circuit is very flexible and extremely thin, and can be attached to human skin.

The British "Nature Nanotechnology" magazine pointed out that the single-layer molybdenum material shows good semiconductor properties, some of which exceed the widely used silicon and research popular graphene, and are expected to become the next generation of semiconductor materials.

The characteristics of molybdenum plate VCMT Insert are that the color, particle size, surface characteristics, dispersity, rheology, thixotropy and crystal form can be manually adjusted, and the product also has high chemical purity, strong chemical inertness, good thermal stability, and are not stable under 400 degrees Celsius. In addition, it also has the advantages of low oil absorption rate, low hardness, small wear value, non-toxic, odorless, tasteless, and good dispersibility.

Medical Plastics Guide： Types and Applications of Medical Polymers

April 20, 2023

Milling a curved surface falls under the umbrella of profile/ contour CNC milling. It involves machining irregularly shaped profiles or continuous curves with various degrees (either slanted, concave, or convex). This is a crucial process in getting most of the uniquely shaped bespoke parts done, which requires the CNC machining services providers to have advanced knowledge of the fundamental machining principles and programs.

Fundamentals to Profile CNC Milling

1.? Profile CNC Milling Processes

Before arriving at the final machined part, it will be first subdivided into different categories: roughing/ semi-roughing, semi-finishing, finishing, and super-finishing. The larger the component, the more operation types will be involved. It is important to sub-categorize the operations in machining a work part so that you would be able to maximize the full potential of the tooling and parameters you will be DCMT Insert using.

Roughing- This operation is always the first stage of machining and usually begins with cutting the raw material block to shape the part approximately near the desired shape or profile, leaving enough metal stock for further operations.

Semi-finishing- This process involves machining the part as per dimension requirements or removing the remaining stock on the part. Semi-finished parts may also be subjected to further processing to achieve a specific requirement for surface finish.

Finishing- This process comes after the semi-finishing operation. Finishing is done to improve the part’s surface finish by removing obvious burrs and other surface flaws. In this operation, it is essential to use high-performing tools because this will significantly affect the work part’s final CCGT Insert appearance.

Super-finishing- the operation goes further until super-finishing if the parts require a mirror finish or a super smooth profile. For this to be achieved, high-speed machining techniques and high-precision tools are used.

2.? Get to Know the Tools Used in CNC Milling Curved Surface

To come up with smooth-curved surfaces on a part being fabricated, different variations of rounded end mills are used. These include rounded inserts, ball nose indexable end mills, and ball nose solid carbide. Round-profiled toolings are preferred for contouring applications because it does not leave evident marks of the tool path.

Insert-type end mills with rounded inserts- These tools often come in large tooling diameters. Rounded insert type end mills are well suited for roughing operations due to their high stability and impressive productivity.

Solid ball nose end mill- These end mills can leave a very nice surface finish on a machined part. They may have low stability due to their structure. That is why they are more commonly used for finishing than for roughing operations.

Indexable head ball nose end mills- Indexable head end mills are similar to solid carbide end mills but have exchangeable heads. These special toolings have a detachable end which may be replaced when needed.

General Tips for CNC Milling Curved Surfaces

1.? Necessary Preparations

Before deciding to fabricate your custom parts through profile milling, it is also essential that you become aware of the various factors that may affect the whole CNC milling process. In addition to this, there are specific things you need to identify so that you can properly choose the suited machining technique. Below are some of the things you need to be prepared about:

Be mindful of the cavity depths of your part designs- This plays a significant role in helping you choose the right cutting tools to use and how long will be the gauge length you will be needing.Know how much material will be subtracted from the raw block- This will help you plan for the operations required in fabricating your work part, whether you will need additional procedures after semi-finishing and semi-roughing.Consider how you will clamp the workpiece in place- This will help you prepare for the necessary fixtures you will be needing.

2.? The Old And Classic: Get Your Feeds And Speeds Right

Feeds and speeds determine the rate of material subtraction on the parts, which is why they have a significant impact in achieving an excellent surface finish. For this, calculations are needed to be followed. Feed rates to be used may also be dependent on the depth of cut, the tooling used, the material to be cut, the profile of the part being machined, and the accuracy required.

Disclaimer: We will not mention actual values for the speeds and feeds in this article because these values may vary depending on multiple factors. It is still recommended to refer to trusted references for the actual speed and feeds. Nevertheless, here are the basic rule of thumbs:

The depth of cut and feed rate varies depending on the hardness of the materials being machined. Take note that for harder materials, the feeds and depth of cut are much lower than that of softer materials like aluminum. Furthermore, the harder the material to be cut, the faster the cutting speed should be.

Feed rates and depth of cut for roughing operations are much more aggressive than finishing operations. It is the combination of using high-speed techniques and the right tools that make an excellent surface finish.

3.? Tooling Utilization

There are many variations of tools available in the market nowadays. For roughing operations, tooling rigidity should be prioritized to withstand the aggressive cut depth and feed demands of roughing. On the other hand, for finishing operations, the end mills should be very sharp not to leave any evident trace of the tool path. Another difference is the tool diameter used. Typically, roughing tools have larger diameters than that of the finishing tools.

4.? Minimize Vibration In Your CNC Milling Processes

Vibration is one of the major causes of undesirable surface finish, chatter, and cutting tool damage. During a milling operation, the vibrations may be coming from multiple sources, including clamping stability, tool rigidity, material hardness, and inaccuracies in the machine spindle. Below are some of our tips to minimize this machining obstacle:

Use tools with good runout accuracyAvoid having too long overhang in your end mills during roughing operations. Instead, use extension bars or extension tool holdersSecure your work holding fixtures by ensuring that proper grip and balance are maintained during the cutting operations.Avoid aggressive cuts when dealing with hard metals.

Conclusion

CNC milling curved surfaces are usually subdivided into different operations (roughing, semi-finishing, finishing, and superfinishing) so that the desired profile is achieved gradually. The toolings used for this type of milling typically have rounded profiles or what is commonly called ball nose end-mills. In summary, CNC milling a curved surface involves doing the necessary preparations, getting the feeds and speeds right, being mindful of the tools you will be using, and minimizing vibrations.