- Carbide brazed tip

Carbide brazed tip

Carbide brazed tips are cutting tool inserts that consist of a small piece of carbide material securely bonded to a tool body or shank through a brazing process. The carbide material used in these tips is known for its exceptional hardness, wear resistance, and overall durability. The brazing process involves heating the carbide tip and the steel body to a high temperature and then fusing them together using a filler material.

One of the primary advantages of carbide brazed tips is their hardness. Carbide is significantly harder than high-speed steel (HSS), which makes these tips more resistant to wear and allows them to maintain sharp cutting edges for longer periods. The higher hardness also enables the tips to withstand higher cutting speeds and feeds, leading to increased productivity and improved machining efficiency.

Carbide brazed tips are incredibly versatile and find applications in a wide range of machining operations, including turning, milling, drilling, and boring. They can be used to machine various materials such as steels, cast iron, non-ferrous metals, and composites. The versatility of carbide brazed tips makes them suitable for both general-purpose and specialized applications.

Introduction

Carbide brazed tips are cutting tool inserts made by brazing a small piece of carbide material onto a tool body or shank. Carbide is a hard and wear-resistant material known for its excellent cutting performance and durability. The brazing process involves fusing the carbide tip onto a steel body, forming a strong and rigid tool.

Carbide brazed tips are widely used in various machining operations, including turning, milling, drilling, and boring. They offer several advantages over traditional high-speed steel (HSS) tools: hardness and wear resistance, cutting speed and efficiency, versatility, surface finish.

Composition and Structure

Carbide brazed tips consist of tungsten carbide or cemented carbide materials bonded to a steel tool body. The carbide provides hardness and wear resistance, while the tool body offers support. A brazing process fuses the carbide and tool body using a filler material. The geometry and coatings of the carbide tip can be customized for specific machining applications.

Hardness

Carbide brazed tips exhibit exceptional hardness due to the tungsten carbide or cemented carbide material. Their hardness allows for effective cutting of various materials and provides resistance against wear, thus extending the tool’s lifespan.

Wear Resistance

Carbide brazed tips are highly wear-resistant, making them suitable for prolonged use in demanding machining applications. Their wear resistance ensures that the cutting edges stay sharp for longer, reducing the frequency of tool changes.

Toughness

The combination of carbide particles and a binder, typically cobalt, enhances the toughness of carbide brazed tips. This toughness enables them to withstand high cutting forces and prevents chipping or breakage during machining operations.

Toughness

Carbide brazed tips can withstand high temperatures generated during cutting. This heat resistance allows them to maintain their structural integrity and cutting performance even under challenging machining conditions.

High Speed Cutting

Carbide brazed tips are well-suited for high-speed cutting operations. Their hardness, wear resistance, and heat resistance enable them to withstand the higher cutting speeds, resulting in improved productivity and efficient machining.

Versatility

Carbide brazed tips can be used for a wide range of machining applications, including turning, milling, drilling, and boring. They are compatible with various materials, such as steels, cast iron, non-ferrous metals, and composites.

Surface Finish

Carbide brazed tips can produce high-quality surface finishes on machined parts. The sharp cutting edges and reduced tool deflection contribute to achieving superior surface finishes.

Cost-Effectiveness

Although carbide brazed tips may have a higher upfront cost compared to other cutting tools, their longer tool life and increased productivity deliver cost savings in the long run.

Carbide Material Preparation

The process starts with the preparation of the carbide material, typically tungsten carbide. Tungsten carbide powder is mixed with a binder material, often cobalt or another metal, to form a homogeneous mixture.

Pressing

The prepared carbide mixture is then compacted under high pressure using specialized equipment such as a press. This process, known as pressing or compacting, gives the carbide its desired shape and density.

Pre-Sintering

This involves heating the parts in a furnace at a specific temperature to remove any binders and to partially bond the carbide particles together. This pre-sintering step prepares the carbide for the final sintering process.

Sintering

They are placed in a high-temperature furnace and subjected to extreme heat. Sintering causes the carbide particles to bond together, resulting in a solid and dense carbide material.

Grinding and Shaping

The sintered carbide material is then carefully ground and shaped to achieve the desired geometry of the carbide tips. This process involves precision grinding machinery.

Tool Body Production

In parallel with the carbide manufacturing process, the tool bodies are produced using materials like high-quality steel. The tool bodies are shaped and machined to provide the necessary support and stability.

Brazing

The brazing filler material is applied between the carbide tip and the tool body. The assembled parts are then heated in a controlled environment, allowing the filler material to melt and create a metallurgical bond between the carbide and the tool body.

Finishing and Coating

This includes checking the dimensions, surface finishes, and ensuring the overall quality of the tips. Additionally, coatings such as TiN or TiCN may be applied to enhance the wear resistance and performance of the carbide tips.

Metal Cutting

Carbide brazed tips are widely used in metal cutting applications, particularly in machining operations. They are commonly applied in turning, milling, drilling, and threading processes to cut and shape various metals such as steel, stainless steel, cast iron, and aluminum. Carbide brazed tips offer high cutting speeds, excellent heat resistance, and prolonged tool life, making them ideal for demanding metal cutting tasks.

Woodworking

Carbide brazed tips are also utilized in woodworking applications. In woodworking operations such as shaping, profiling, and cutting, carbide brazed tips provide superior cutting performance and durability. They can handle the high speeds and tough conditions encountered in woodworking, providing clean and precise cuts on wood, plywood, particleboard, and other wood-based materials.

Mining and Construction

Carbide brazed tips are extensively used in mining and construction industries for cutting and drilling applications. They are commonly employed in rock drilling, tunneling, and excavation activities. Carbide tips exhibit excellent resistance to abrasion and impact, allowing them to withstand the harsh conditions encountered in mining and construction operations.

Wear Parts and Wear Protection

Carbide brazed tips are employed as wear parts and wear protection components in various industries. They are used in applications where resistance to abrasion, erosion, and wear is crucial. For example, carbide brazed tips are used in the manufacturing of wear plates, wear rings, wear bars, and cutting tools for agricultural machinery, earthmoving equipment, and industrial machinery.

Metal Cutting

Woodworking

Mining and Construction

Wear Parts and Wear Protection

What are carbide brazed tips?

Carbide brazed tips are cutting tools that feature a tungsten carbide tip brazed onto a tool body, typically made of a softer metal. The brazing process involves using a filler metal to create a strong bond between the carbide tip and the tool body. This combination leverages the hardness and wear resistance of tungsten carbide with the toughness and flexibility of the tool body material, resulting in a highly effective cutting tool.

What are the benefits of using coated tungsten carbide brazed tips?

Coatings enhance wear resistance, reduce friction, improve chip flow, and increase tool life, especially in demanding applications involving high temperatures or abrasive materials.

Can carbide brazed tip blades be sharpened and reconditioned?

Yes, they can be sharpened multiple times using specialized grinding wheels and techniques. However, it’s crucial to maintain the original blade geometry and avoid overheating during grinding.

What are cemented carbide brazed tip inserts?

Cemented carbide brazed tip inserts are cutting tools that feature a carbide tip brazed onto a tool body, providing exceptional hardness and wear resistance.

What are applications of carbide brazed tips?

Cutting Tools: For turning, milling, and boring.
Woodworking Tools: Such as saw blades and routers.
Mining and Drilling: Drill bits and cutter heads.
Metalworking: For machining and shaping metals.
Wear Parts: In industrial machinery for enhanced durability.

Are there different types of carbide grades for brazed tips?

Yes, there are several carbide grades available for brazed tips, each with specific properties suited for different applications. Common carbide grades include C1, C2, C5, and C6.

What are the pros and cons of carbide brazed tip inserts?

Advantages include exceptional hardness, reduced friction and wear, improved heat resistance, longer tool life, and enhanced cutting performance. Disadvantages include higher cost, need for specialized equipment, potential brittleness under heavy impact, complex manufacturing process, and possible coating peel-off.

What is carbide brazed tip geometry?

Carbide brazed tip geometry refers to the shape, angles, and dimensions of the cutting edge and surfaces of the tip. Key geometric parameters include:

Rake Angle: The angle between the cutting edge and the workpiece surface. It influences chip formation and cutting force.
Relief Angle: The angle between the flank of the tool and the workpiece surface, preventing rubbing and reducing friction.
Cutting Edge Angle: The angle formed by the intersection of the rake and flank faces, affecting the tool’s strength and wear resistance.
Corner Radius: The rounded edge at the tool’s tip, impacting surface finish and tool life.

How does the rake angle affect cutting performance?

The rake angle influences chip formation and cutting forces. A positive rake angle reduces cutting forces and improves efficiency but may compromise tool strength.

What is the difference between a round insert and a square insert Type F tip?

Round inserts with small nose radii provide a good balance of sharpness and strength for general-purpose finishing and contouring, while square inserts with sharp corners are ideal for finishing flat surfaces and creating precise 90-degree shoulders.

GB Brazed Tips Data

For Making Periphery Turning Tools, Boring Tools and Grooving Tools

Classification	L/mm	t/mm	S/mm	e/mm	α°
A1-0605-025	6	5	2.5	/	0
A1-0807-030	8	7	3.0	/	0
A1-1006-035	10	6	3.5	0.8	14
A1-1210-040	12	10	4.0	0.8	14
A1-1412-045	14	12	4.5	0.8	14
A1-1412-040	14	12	4.0	0.8	14
A1-1610-055	16	10	5.5	0.8	14
A1-1610-045	16	10	4.5	0.8	14
A1-1812-070	18	12	7.0	0.8	14
A1-1812-065	18	12	6.5	0.8	14
A1-1816-060	18	16	6.0	0.8	14
A1-1812-060	18	12	6.0	0.8	14
A1-2012-070	20	12	7.0	0.8	14
A1-2215-085	22	15	8.5	0.8	14
A1-2215-075	22	15	7.5	0.8	14
A1-2218-070	22	18	7.0	0.8	14
A1-2515-085	25	15	8.5	0.8	14
A1-2520-100	25	20	10.0	0.8	14
A1-3016-100	30	16	10.0	0.8	14
A1-3620-100	36	20	10.0	0.8	14
A1-4018-105	40	18	10.5	1.2	14
A1-5020-105	50	20	10.5	1.2	14
A1-6022-105	60	22	10.5	1.2	14
A1-7025-120	70	25	12.0	1.2	14

Classification		L/mm	t/mm	S/mm	R/mm	rℇmm	e/mm	α°
R.H.	L.H.	L/mm	t/mm	S/mm	R/mm	rℇmm	e/mm	α°
A2-0807-025	/	8	7	2.5	7	0.5	/	0
A2-1008-030	/	10	8	3.0	8	1.0	/	0
A2-1210-045	/	12	10	4.5	10	1.0	0.8	14
A2-1614-060	A2-1614-060LH	16	14	6.0	14	1.0	0.8	14
A2-2018-070	A2-2018-070LH	20	18	7.0	18	1.0	0.8	14
A2-2520-080	A2-2520-080LH	25	20	8.0	20	1.0	0.8	14

Classification	L/mm	t/mm	S/mm	R/mm	e/mm	α°
B2-0808-030	8	8	3.0	4.0	/	/
B2-1010-035	10	10	3.5	5.0	0.8	14
B2-1212-045	12	12	4.5	6.0	0.8	14
B2-1416-050	14	16	5.0	8.0	0.8	14
B2-1620-060	16	20	6.0	10.0	0.8	14
B2-2025-070	20	25	7.0	12.5	0.8	14
B2-2530-080	25	30	8.0	15.0	0.8	14
B2-2835-090	28	35	9.0	17.5	0.8	14

Classification	D/mm	d/mm	H/mm	R/mm
B4-283100-100	28.3	10	10	35.0
B4-330120-100	33.0	12	10	35.0
B4-465150-120	46.5	15	12	41.7

Classification	L/mm	t/mm	S/mm	rℇmm	e/mm	α°
C1-1004-030	10	4	3	0.5	/	/
C1-1606-040	16	6	4	0.5	0.8	10
C1-2008-050	20	8	5	0.5	0.8	10
C1-2210-060	22	10	6	0.5	0.8	10
C1-2512-070	25	12	7	0.8	0.8	10

Classification	L/mm	t/mm	S/mm	rℇmm
C1-A-1065-028	10	6.5	2.8	0.5
C1-A-1608-030	16	8.0	3.0	0.5
C1-A-2010-040	20	10.0	4.0	0.5

Classification	L/mm	t/mm	S/mm	b/mm	e/mm
C2-1507-040	15	7	4	1.8	0.8
C2-1810-050	18	10	5	3.1	0.8
C2-2314-050	23	14	5	4.9	0.8
C2-2818-060	28	18	6	7.7	0.8
C2-3628-070	36	28	7	13.1	0.8

Classification	L/mm	t/mm	S/mm	e/mm	α°
C3-03512-030	3.5	12	3	/	/
C3-04514-040	4.5	14	4	0.8	14
C3-05517-050	5.5	17	5	0.8	14
C3-06517-060	6.5	17	6	0.8	14
C3-06510-060	6.5	10	6	0.8	14
C3-08520-070	8.5	20	7	0.8	14
C3-08511-070	8.5	11	7	0.8	14
C3-10522-080	10.5	22	8	0.8	14
C3-10512-080	10.5	12	8	0.8	14
C3-12522-100	12.5	22	10	0.8	14
C3-12512-100	12.5	12	10	0.8	14
C3-16525-110	16.5	25	11	1.2	14

Classification	L/mm	t/mm	S/mm	b/mm	e/mm
C4-2012-050	20	12	5	3.0	0.8
C4-2516-050	25	16	5	4.0	0.8
C4-3020-060	30	20	6	5.5	0.8

Classification	L/mm	t/mm	S/mm	K/mm	R/mm	e/mm
E3-12060-015	12	6.0	1.5	1.5	20	/
E3-15035-020	15	3.5	2.0	1.5	20	/
E3-15070-020	15	7.0	2.0	1.5	20	/
E3-20045-025	20	4.5	2.5	2.5	25	/
E3-20060-035	20	6.0	3.5	2.5	25	0.5
E3-20090-025	20	9.0	2.5	2.5	25	/
E3-25080-030	25	8.0	3.0	3.5	30	0.5
E3-25150-030	25	15.0	3.0	3.5	30	0.5
E3-30100-040	30	10.0	4.0	3.5	30	0.5
E3-30090-040	30	9.0	4.0	3.5	30	0.5
E3-30210-040	30	21.0	4.0	3.5	30	0.5
E3-35100-050	35	10.0	5.0	3.5	30	0.8
E3-40120-050	40	12.0	5.0	3.5	30	0.8
E3-45120-060	45	12.0	6.0	3.5	30	0.8

Classification	L/mm	B/mm	B1/mm	C/mm	R/mm
S-A-16070-020	16	7.0	6.3	2	3
S-A-20106-030	20	10.6	9.5	3	4
S-A-25145-045	25	14.5	12.9	4.5	4
S-A-30180-045	30	18.0	16.0	4.5	4

Classification	L/mm	t/mm	S/mm	r/mm	α°
A5	5	3	2	2	/
A6	6	4	3	3	/
A8	8	5	3	3	/
A10	10	6	4	4	18
A12	12	8	5	5	18
A16	16	10	6	6	18
A20	20	12	7	7	18
A25	25	14	8	8	18
A32	32	18	10	10	18
A40	40	22	12	12	18
A50	50	25	14	14	18

Classification	D±Tol./mm	C±0.13/mm	r/mm
T-0-07-05	7.34±0.08	3.30	0.5
T-0-10-05	10.34±0.08	3.85	0.5
T-0-13-05	13.45±0.13	4.85	0.5
T-0-13-10	13.45±0.13	4.85	1.0
T-0-16-10	16.50±0.18	5.85	1.0
T-0-16-15	16.50±0.18	5.85	1.5
T-0-16-20	16.50±0.18	5.85	2.0

Classification	D±Tol./mm	C±0.13/mm	r/mm
T-8-07-05	7.34±0.08	3.30	0.5
T-8-10-05	10.34±0.08	3.85	0.5
T-8-13-05	13.45±0.13	4.85	0.5
T-8-13-10	13.45±0.13	4.85	1.0
T-8-16-05	16.50±0.18	5.85	0.5
T-8-16-10	16.50±0.18	5.85	1.0
T-8-16-20	16.50±0.18	5.85	2.0

Classification	L/mm	t/mm	S/mm	f/mm	K/mm	R/mm	e/mm
E4-15040-020	15	4.0	2.0	2.5	1.5	15	/
E4-18050-025	18	5.0	2.5	3.5	1.5	20	/
E4-20060-030	20	6.0	3.0	5	1.5	25	0.5
E4-25080-035	25	8.0	3.5	6	2	25	0.5
E4-30100-040	30	10.0	4.0	8	2	30	0.5

Classification	L/mm	t/mm	S/mm	K/mm	R/mm	e/mm
E5-15025-013	15	2.5	1.3	1.5	20	/
E5-18030-015	18	3.0	1.5	1.5	25	/
E5-22035-020	22	3.5	2.0	1.5	25	/
E5-25040-025	25	4.0	2.5	2	30	/
E5-30050-030	30	5.0	3.0	2	30	0.5
E5-40060-035	40	6.0	3.5	2	30	0.5

Classification	D/mm	L/mm	r/mm
F1-0815	8	15	1.0
F1-1014	10	14	1.0
F1-1220	12	20	1.5
F1-1524	15	24	1.5
F1-1828	18	28	2.0
F1-2435	24	35	2.0
F1-3040	30	40	2.5
F1-3650	36	50	2.5
F1-4060	40	60	3.0

Classification	L/mm	B/mm	C/mm	R/mm
F2-16080-050	16	8.0	5.0	4
F2-16100-050	16	10.0	5.0	5
F2-16120-060	16	12.0	6.0	6
F2-18025-025	18	2.5	2.5	1.25
F2-20030-030	20	3.0	3.0	1.5
F2-25050-040	25	5.0	4.0	2.5
F2-30060-050	30	6.0	5.0	3
F2-30080-050	30	8.0	5.0	4
F2-30100-050	30	10.0	5.0	5
F2-30120-060	30	12.0	6.0	6
F2-35080-050	35	8.0	5.0	4
F2-30080-050	30	8.0	5.0	4
F2-45120-060	45	12.0	6.0	6

Classification	D/mm	L/mm
F3-3510	3.5	10
F3-4512	4.5	12
F3-5515	5.5	15
F3-6518	6.5	18
F3-7520	7.5	20
F3-8522	8.5	22

Classification	L/mm	B/mm	B1/mm	C/mm	R/mm	e/mm
S-B-2522-045	25	22	14	4.5	8	0.8
S-B-3028-050	30	28	17	5.0	8	0.8
S-B-3533-060	35	33	20	6.0	10	1.2
S-B-4040-060	40	40	23	6.0	10	1.2

Classification	L/mm	t/mm	S/mm	r/mm	α°
A5	5	3	2	2	/
A6	6	4	3	3	/
A8	8	5	3	3	/
A10	10	6	4	4	18
A12	12	8	5	5	18
A16	16	10	6	6	18
A20	20	12	7	7	18
A25	25	14	8	8	18
A32	32	18	10	10	18
A40	40	22	12	12	18
A50	50	25	14	14	18

Classification	L/mm	t/mm	S/mm	r/mm	α°
B5	5	3	2	2.0	/
B6	6	4	3	2.5	/
B8	8	5	3	3.0	/
B10	10	6	4	4.0	18
B12	12	8	5	5.0	18
B16	16	10	6	6.0	18
B20	20	12	7	7.0	18
B25	25	14	8	8.0	18
B32	32	18	10	10.0	18
B40	40	22	12	12.0	18
B50	50	25	14	14.0	18

Classification	D±Tol./mm	C±0.13/mm	r/mm
T-11-07-05	7.34±0.1	3.30	0.5
T-11-10-05	10.34±0.1	3.85	0.5
T-11-13-05	13.45±0.15	4.85	0.5
T-11-13-10	13.45±0.15	4.85	1.0
T-11-13-05	13.45±0.15	5.10	0.5
T-11-16-05	16.50±0.18	5.85	0.5
T-11-16-10	16.50±0.18	5.85	1.0

Classification	D±Tol./mm	C±0.13/mm	r/mm
S-0-10-05	10.4±0.08	3.85	0.5
S-0-13-05	13.4±0.13	4.85	0.5
S-0-13-10	13.4±0.13	4.85	1.0
S-0-16-05	16.5±0.18	4.85	0.5
S-0-16-10	16.5±0.18	4.85	1.0
S-0-19-10	19.6±0.18	5.85	1.0
S-0-19-20	19.6±0.18	5.85	2.0
S-0-25-10	25.6±0.25	7.35	1.0
S-0-25-20	25.6±0.25	7.35	2.0

- Carbide brazed tip