Hard metals metaltech report
- April 25, 2012
Solid carbide thread mills
Emuge Corp. has expanded its line of solid carbide thread mills in its Threads-All program.
Requiring only eight standard tool sizes, #10 – 1/4 - 5/16 – 3/8 – 7/16 -1/2 – 5/8 – 3/4, it is now possible to produce 100 plus commonly produced screw thread designations. In addition, the new tools provide control over pitch diameter limits including 2B, 3B, 3BG and all oversize variants.
The tools are designed for difficult-to-cut materials, up to 58Rc, including stainless steels, titanium and Inconel, often used in demanding industries such as aerospace, defense and medical.
Inconel 718 belongs to a family of nickel based superalloys used extensively for applications where withstanding high temperatures and high corrosion resistance is required. The major problems encountered when machining Inconel 718 are characterized by high temperatures on the cutting edge of the insert due to the abrasive elements in the material composition (high nickel content of 50-55 per cent and chrome 17-21 per cent) which causes high wear rates, chipping, notching and insert breakage.
IC806 is a submicron grade with superior wear resistant properties and advanced PVD TiAlN. It has a hard submicron substrate with PVD coating and a special post coating treatment which provides substantially improved tool life and better reliability.
Hard turning, generally defined as the use of high hardness polycrystalline cubic boron nitride (PCBN) inserts for machining hardened ferrous or superalloy materials, is poised for growth. In continuous-cut operations, chip control can be an issue. The hard inserts produce ribbons of chips that quickly turn into “bird nests,” that can damage the part’s surface finish and slow the process.
To address this, Kennametal has integrated chip breaking geometries into two of its hardest PCBN grades–KB5610 and KB5625. “Ideally, hardened steels are machined with a low or medium PCBN content grades in continuous cutting applications,” says Gabriel Dontu, global superhard technical leader. “However, until recently, the industry has not been able to add
chip-breaking technology to CBN inserts. KB5610 with chip breaker is the first product of its type to deliver chip breaking performance where it’s most needed.”
The PCBN inserts feature a PVD coating and new braze technology for improved braze joint strength even under the most demanding cutting conditions.
Solid carbide shank milling cutters
Derived from multiple special tooling solutions for various clients, Komet has assembled a standard range of solid carbide cutting tools sold under the JEL brand. The solid carbide shank milling cutters’ range provides tools to meet all demands in the 3.0 - 25.0 mm diameter range.
• End milling cutters
• Roughing end mills
• HPC milling cutters
• Spherical cutters
• Torus milling cutters
• Chamfer milling cutters
• Radius milling cutters
While these tools can be used for machining a variety of materials, from cast iron to steel materials, and to aluminum and non-ferrous metals, a number of them are specifically designed for machining hardened steels up to 65 HRC. The range of milling cutters provide a reliable solution for milling machining operations.
OSG Canada’s Exocarb WXL-WXS series end mills for hard milling applications feature special carbide substrates and geometries as well as OSG’s WXL coating, which has higher surface hardness and oxidation temperatures than standard TiALN
coatings, allowing WXL end mills to excel in demanding wet or dry milling applications in non ferrous, mild steels, and hardened steels up to 55Rc.
The end mills offer superb performance in hardened materials up to 70Rc. Here is how: WXS coating has a high oxidation temperature (1300ºC) and surface hardness (3500Hv) for high spindle speeds—that generate more heat which actually improves the WXS coatings surface lubricity, extends tool life and reduces cycle times.
end mills for profiling in medium hard to hard steels.
The end mills come in diameters from 0.1 - 12 mm and are suitable for all small die and mould, electronic fiber optic connector and
medical tooth implant manufacturing, where high precision is important.
Produced in a fine-grained solid carbide grade with multi-layered PVD coating, the tools have a geometry design which prevents the radius from deteriorating from uneven wear. The long neck allows for good accessibility, especially in pocket milling.
The JHP770 is designed for machining in titanium while the JHP780 is suitable for heat resistant superalloys typically found in aerospace components. Features of the JHP770 include differential flute spacing, to avoid vibrations, a polished Siron-A coating for increased tool life, optimized edge preparation, radial relief, special formed chip space and an internal central coolant channel for optimized flow. The JHP780 is also designed with differential flute spacing to avoid vibrations, and features a polished Mega 64 coating for longer tool life. The double core adds stability, and edge preparation is also optimized.
SGS Tool’s patented Z-Carb-AP Variable Rake end mill is designed for chatter suppression. With most end mills, the cutting teeth enter and exit the material creating a natural rhythm that results in damaging harmonics. The harmonics produce a frequency that resonates through the entire tool, resulting in one of the most damaging forms of cutter wear known as chatter. The Z-Carb-AP, with its patented geometry, offers three stages of chatter suppression resulting in a quiet and stable milling experience.
By incorporating the Variable Rake Geometry, the Z-Carb-AP can alter and control the cutting dynamic like no other tool available, which takes chatter suppression to a whole new level of advanced productivity.
Small diameter hard part machining
Walter USA, LLC’s new Walter Prototyp Proto·max Ultra ball-nose end mill is the latest generation of the company’s Proto·max solid carbide milling tools, which offer enhanced machining performance and tool life, even when machining hard ISO-H materials.
The new end mills come in two different diameter ranges: the standard versions from 3 to 12 mm diameter and the mini versions for small to extremely small contours, ranging from 0.1-2.5 mm. For the smaller diameter range, the Proto·max Ultra’s reduced neck and its reach of up to 10xD are beneficial for the machining of deep cavities. This results in excellent concentricity properties, which are essential at the high speeds achieved by small tool diameters.
It’s suitable for hardened materials up to 70 HRC in die and mouldmaking, as well as similar operations in general machining and heavy construction applications.
Nano-grade carbide end mills
The X5070 is a range of upgraded premium carbide end mills, nano-grain size, designed for machining hardened materials in a range of 50-70 HRc. They can be used in high speed cutting methods (HSC), dry cut, machining die and mould steels and tool steels.
The endmills are harder than conventional carbide but have almost the same toughness. They have a fine nano-grain size and uniform carbide particles, providing better wear resistance, which significantly prolongs tool life. In addition, they have a superior hot hardness material heat barrier that permits a higher cutting temperature and provides greater hot hardness at the tool/chip interface; most of the heat is carried away with the chips.
The tools are coated with the company’s coating for the upper range of hardened material, which combines high hardness (over 4500 HV) and high thermal stability against oxidation (1200o C.), and low coefficient of friction against steel.