TUNGSTEN CARBIDE INSERTS,CEMENTED CARBIDE WEAR PADS,TUNGSTEN CARBIDE INSERTS

What are corn end mills？

Zhu Zhou Estool Corn End Mills, also known as corn cob end mills, and scaly end mills. For Corn end mill, they have dense spiral mesh on the surface, and the groove is relatively shallow. Carbide corn end mills are generally used for processing functional materials , especially like some composite materials such as carbon fiber Kraft materials (like the outer shell of airplane’s wing) ,such as fiberglass.Solid carbide Corn end mills are composed of numerous cutting units, which have very sharp cutting edges, greatly reduces the cutting resistance.Moreover, high-speed cutting can be realized, the effect of replacing grinding with milling is achieved, the processing efficiency and surface quality of composite materials are improved, and the APKT Insert service life of the end mill is prolonged.Zhu Zhou Estool solid carbide corn end mills has advantages as below:1.Double-edged positive and negative spiral chip removal structure for long service life2.Sharp edge and high wear resistance, professionally designed for wood milling.3.Cutting the upper and lower sides smooth and burr-free.4. Large spiral flute, imported tungsten steel base materialWelcome to contact for more details.Related search keywords:carbide corn end mills, carbide corn end mills, carbide corn teeth end mills,carbide wear parts,carbide end mill aluminum,3/8 carbide end mill bit,carbide end mill cutting speed,carbide end mill for aluminum,carbide end mill for wood,carbide end mill hrc 55,carbide end mill length,carbide end mill material,carbide ball nose end mill,tungsten carbide,carbide blades, carbide burrs,carbide DNMG Insert dies The Carbide Milling Inserts Blog: https://millinginserts.blog.ss-blog.jp/

Considerations for Properly Implementing Advanced Tool Materials

Other than HSS taps, our current tool inventory is all carbide and we’ve settled on some satisfactory grades and coatings for our applications. We are open to exploring more advanced tool materials like PCD but need some guidance on justifying the cost and secondary considerations. How do you view these and justify their fit in your processes?

We often forget how adaptable carbide can be given its interchangeable nature in typical systems, whether it be end mills, shell mill inserts or turning inserts. When we want a process improvement, we can simply reach for a new geometry, flute count or coating and off we go, often with minimal changes needed or cost added. However, as part requirements become more difficult, we may reach the upper end of carbide’s capability, which is where advanced tool materials like polycrystalline diamond (PCD), monocrystalline diamond (MCD), cubic boron nitride (CBN) and ceramic come into play. Sometimes called “exotics”, these can be a very exciting addition to any process, but the cost justification and the process adaptations require careful consideration. 

To understand where they all fit, let’s start with a simple approach. Most cutting processes fall into two buckets: roughing or finishing. To put it more specifically, is the task in question to move metal out of the way, or is the task to put down a smooth, accurate surface?

If roughing is identified as an area for improvement, then a simple comparison of metal removal rates for your current process and one with an exotic is appropriate. From there, you can extrapolate this for total machine time saved for the year and apply the burden rate. Is the added cost of the tool amortized with the savings? If so, then it’s probably a winning application for an advanced tool.

For finishing, a deeper look at the overall project requirements may be required. A new, sharp, carbide tool can make incredible finishes when setup properly and with the right parameters; however, where advanced materials shine is their ability to achieve an even better finish while also maintaining this finish over long part runs due to their enhanced wear resistance. Therefore, a prototype application may be fine with a traditional carbide tool, knowing only a short run of parts are needed. A production application may view this differently when looking at runs of 1000 or more parts. In this case, the justification is simple, as it’s a must have to meet customer requirements.

Beyond the more obvious justifications above, there are others worth a look for your shop. In the case of PCD and CBN, tool manufacturers often make these tool materials available for existing turning and shell mill insert pockets, which means there is no added cost for durable tooling. This decreases the barrier and cost of entry and enables your shop to experiment before investing in more dedicated tool inventory.

In the case of shell mills, we may only need to dedicate a single pocket to the use of diamond or CBN. A single wiper insert is often enough to leave the desired finish while the rest of the inserts are traditional carbide. Now the cost of that single insert, even at 10X, can be amortized over a greater part of the total tool assembly cost.

Lastly, another benefit for PCD and CBN is their ability to do roughing and finishing duties. You may be able to replace two tool assemblies in a process with a single tool, which saves tool cost, but will also improve overall process efficiency and cycle time.

One thing shops may get wrong when getting into advanced tooling is incorrectly assuming these tools are plug and play. The tools may fit into existing tool holders, or even into the same shell mill pockets or turning pocket as carbide inserts, but that’s where the similarities end. Advanced tooling runs at higher surface speeds which means more rpm and more heat. These tools are also more brittle.

Tool holders need more care for balance and runout to accommodate the elevated speeds and reduce vibration. Also, the way we enter and exit a cut can hurt the insert, so take some time to revisit your toolpaths and programming to ease into things.

Coolant systems also need to be equipped for success. A single coolant nozzle lightly splashing the cutting tool will no longer suffice, so make sure the volume and pressure are adequate for the application. In the case of ceramics, we need to make sure we’re working in a very dry environment to not shock the tool.

With all these enablers, make sure you are accounting for these upgrades Carbide Milling Insert with your overall cost model for advanced tooling. You could miss key cost adders during implementation, or realize you need to make this a longer-term improvement project, investing over time with holders, a coolant system and then finally the advanced tools. A thorough understanding of the required adaptations from the supporting cast — process and people alike — are the secret to unlocking any exotic’s full potential.

One quick point is that most of the above tool materials can be incorporated into abrasive tooling as well. If a traditional chip-making process cannot achieve what you need, an abrasive process may be an option. However, the above comments about tool holders and coolant systems are amplified even more with abrasives, including the need for a machining center with properly sealed TCMT Insert guideways and coolant filter system to resist the new grit in the process.

As shops and businesses, we must manage money in and money out. The added cost of more advanced tool materials often will reap benefits long term, but can also unlock new capabilities for finish and consistency that your shop didn’t previously have. Be sure to review the full picture and not get caught up in sticker shock.

The http://philiposbo.mee.nu/ Blog: http://philiposbo.mee.nu/

T Codes Simplify Tool Length Confirmation Process

Tool length compensation simplifies programming and enhances trial machining and sizing during setups and production runs. It also makes it possible to assemble and measure cutting tool lengths using an offline tool length measuring device.

Though tool length compensation is a good feature, it does have some drawbacks.

1) The cutting tool must be rigid enough to machine using the programmed cutting conditions, and 2) the cutting tool must be long enough to reach the deepest machined surface without being so long that it collides with an obstruction during tool changes.

In some companies, programmers specify the components TCGT Insert for assembling cutting tools along with a range of acceptable lengths.

Many companies, however, specify only the tool name and size, leaving it to the setup person to determine how to assemble cutting tools. Setup people may not know for sure whether each tool will have adequate rigidity, or whether its length is within an acceptable range.

While they may not be able to ensure rigidity, custom macros can solve the cutting tool length range question.

The technique Cemented Carbide Inserts here is especially helpful for machines with limited Z-axis travel, like small vertical machining centers and many horizontal machining centers. We are using FANUC custom macro system variables to access offset-related data, and our example also assumes the machine has FANUC’s standard set of six fixture offsets and the user plans to set the cutting tool length as the tool length compensation offset value.

Variables in the #2200 series provide access to tool length geometry offsets. Those in the #5200 series provide access to fixture offsets. Additionally, our example “second references” the related system variable values. Our test tool length values are:

#149=4.0

#2=#[2200+#149] (Current tool length)

With common variable #149 set to 4.0, the expression 2200+#149 renders 2204. The pound sign (#) outside of the brackets makes this system variable #2204, which accesses the value of tool length geometry offset number four. Similar techniques are used for accessing the currently instated fixture offset Z-register value. We are also using system variable #4014 to access the currently instated fixture offset value (54-59).

Consider the illustration.

Input data comes from offsets, from system constants (#500 series permanent common variables) and from values specified within the program. The offsets include fixture offset Z values and tool lengths entered in the tool length compensation geometry offsets.

Users will only need to enter the following system constants one time:

#511: Clearance for making a tool change.

#512: Tool changer pullout amount (consult machine builder’s documentation).

#513: Z-axis travel (consult machine builder’s documentation).

These values match to the CNC program:

#100: Distance between Z-zero surface to highest obstruction (like a clamp).

#101: Distance between Z-zero surface and the deepest depth. This value can be specified prior to each tool change.

This technique operates from a user-defined T-code program. After setting a parameter (#6001, bit 5 for newer FANUC CNCs) to 1, any time the CNC sees a T code, it will store the T value in common variable #149 and execute program O9000.

There are two common styles of automatic tool changing systems.

With one, the T code by itself completes the tool change. With the other, the T code merely rotates the tool carousel, bringing the tool to the ready station while an M06 command changes the tools. The following example program should work nicely for both, though users may have to separate the T code and the M06 into two commands for the program to execute properly.

Here are the programs. The main program (O6001) is abbreviated to show only the related commands:

O6001 (Main program)

G54 (Select fixture offset)

#100=2.0 (Height of tallest feature/obstruction from fixture offset Z-zero surface)

#101=2.5 (Deepest depth of machining for tool 4)

(.)

(Program startup commands)

(.)

T04 (Calls program O9000, the user-defined T-code custom macro)

M06 (Tool change will occur if tool is within range)

(.)

(Machining with tool station 4)

(.)

#101=1.0 (Deepest depth of machining for tool 5)

(Tool startup commands)

(.)

T5 (Calls user-defined T-code custom macro)

M06 (Tool change will occur if tool is within range)

(Machining with tool 5)

(.)

(Balance of machining program)

(.)

M30

O9000 (Tool checking custom macro)

#1=ABS[#[5203+[#4014-53]*20]] (Current fixture offset Z value)

#2=#[2200+#149] (Current tool length)

IF[[#1-#2-#511-#512-#100]GT0]GOTO5 (Is the tool length okay?)

#3000=100(TOOL IS TOO LONG)

N5#3=#1+#101 (Deepest depth)

#4=#513+#2 (Tool reach)

IF[[#4-#3]GT0]GOTO10 (Will the tool reach deepest surface?)

#3000=101(TOOL TOO SHORT)

N10T#149 (Rotate tool to ready position)

M99

The VBMT Insert Blog: https://vbmtinsert.bloggersdelight.dk

All Directional Turning Cuts Cycle Times 50%

If you thought there’s nothing new in turning, think again. Sandvik Coromant’s new PrimeTurning process offers dramatic improvements over conventional turning, allowing higher speeds and feeds, better chip control, improved tool life, and less time lost cutting air.

We’ll explain more below, but first take a look at this video and you’ll get the picture quickly.

No, the video is not running backwards on some of those cuts. In conventional turning, you feed toward the chuck in the Z axis. But with PrimeTurning you can feed in either direction in turning, facing and shoulder-cutting operations. The results are astonishing. Some operations can be performed in a small fraction of the time required in conventional turning, and with a better surface finish as well.

A Very Different Insert

The CoroTurn Prime inserts come in two configurations. The A-type insert is designed for light roughing, finishing and profiling. With extremely strong corners, the B-type insert is for roughing. A key benefit of their designs is a smaller lead angle relative to the feed direction which allows you to cut substantially faster. This approach spreads cutting forces and heat over a larger portion of the cutting edge, which also contributes to longer tool life.

For some operations, you can literally feed back and forth with the tool virtually never leaving the cut. That’s a huge time-saver particularly in roughing operations requiring multiple passes to get down to the required OD.

Another advantage of the low lead angle (25% for Type B, 35% for Type A) is that it creates a wiper-like action that leaves a better surface finish. That’s particularly advantageous in roughing because it also leaves less work to do in subsequent finishing cuts.  

Still another advantage of the insert shape is the ability to use the entire edge of the insert, and for a variety of operations. You can turn, face or profile with a single tool. That’s more life from an insert. Better yet, it can eliminate multiple tool changes required with less versatile inserts.

Thinking Different About Process

It’s one thing to have these capabilities, but quite another to use them wisely. To that end Sandvik Coromant has online help on how to use CoroTurn Prime tools and the kinds of parts that best lend themselves to the process. In general, the best candidates are short and compact components in chucking applications and longer components with a tailstock.

View Videos

To make the most of the PrimeTurning process you really have to think differently about the cutting APMT Insert strategy because conventional wisdom does not apply. Indeed, that’s the point, because PrimeTurning unlocks the door to much more productive cutting routines. That’s also going to require a new approach part programming, and CAM systems are going to have to catch up to best practices for the process.

To bridge the gap, Sandvik Coromant has developed a PrimeTurning code generator that allows for smooth implementation of the most productive cutting strategies for the process. The easy-to-use software allows several ways to input a turned profile. You can copy-paste existing code, describe the profile with a G71 cycle, or draw the profile in visual mode. The software will then output a new routine in an ISO-compatible format.

But help from CAM vendors is not far off. Mastercam is already in beta test for its tungsten carbide inserts next release which the company has announced will support the PrimeTurning method.

Is PrimeTurning For You?

The more metal you are removing on a part, the more benefit you’ll get from PrimeTurning. Included in the Infographic here is but one example where the process resulted in an 85% increase in productivity.

Download Infographic

As for your parts, you can take a test on Sandvik Coromant’s website to see projected productivity improvements for different kinds of parts, materials, and clamping scenarios.

Is PrimeTurning for everyone? Not necessarily, or at least not yet. Because of the much more aggressive cutting parameters, you won’t want to use it on thin, vibration-prone parts or less stable workholding configurations. But for the parts that do apply, PrimeTurning can dramatically increase productivity in ways that were unthinkable before the advent of this process. Large volume manufacturers are likely to see the greatest benefits for now. Early adopters are going to be people who already well understand turning, and are looking for something more. For those shops, PrimeTurning is poised to offer more than they ever imagined.

The RCGT Insert Blog: https://rcgtinsert.bloggersdelight.dk

Inserts Boost Productivity in Cast Iron

Walter USA’s Tiger-tec Silver line of high-performance inserts now includes the RK 5 and RK7 geometries designed to enhance cutting speed, reliability and tool life in ISO K (cast iron) materials. The new geometries feature a plateau step between the location face and the cutting edge, enabling grinding of the location face after coating. The resulting evenly ground faces ensure that they can be seated with maximum stability, the company says. As a result, the inserts reduce cutting-edge wear, enhance tool life and increase process reliability, particularly in cases of high dynamic loads.

The RK5 is DNMG Insert a classic flat-top insert without a chip groove, designed for speed, reliability and increased tool life, particularly in grey cast iron. RK7 is a robust insert designed for heavy interrupted cuts, large depth-of-cut variations with uneven material removal, and hard cast skin. Its geometry is similar to the RK5 but with a protective chamfer on the cutting edge. This insert is suitable for hard and soft machining of hardened steels ranging from 40 to 62 HRc.

In addition to the new geometries, the company offers the WKK10S and WKK20S Tiger-tec Silver grades suitable for use with grey cast iron, ductile cast iron and compacted graphite cast iron. WKK10S is well-suited for continuous and light interrupted cuts, and is capable of dry machining. WKK20S, a universal cutting grade, can be used for both wet and dry machining and Cutting Tool Carbide Inserts is said to provide high process reliability for workpieces with interrupted cuts, cast skin or cross-holes.

The Milling Inserts Blog: https://millinginserts.mystrikingly.com