Carbide tool inserts are crucial components in modern machining and metalworking processes. They offer superior cutting performance, longevity, and versatility, making them indispensable in various industrial applications. In this comprehensive guide, we’ll delve into everything you need to know about carbide tool inserts, including their types, applications, material properties, and how to select the right one for your needs.
Overview of Carbide Tool Inserts
Carbide tool inserts are replaceable tips used in machining to cut, shape, and finish materials. They are made from carbide, a composite material consisting of tungsten carbide particles bound together with a metal, usually cobalt. This combination gives carbide inserts their renowned hardness and durability. They are used in turning, milling, and drilling operations across various industries, from automotive to aerospace.
種類 Carbide Tool Inserts
Carbide tool inserts come in numerous shapes, sizes, and compositions, each suited for specific tasks and materials. Here’s a table to present the different types of carbide tool inserts:
| インサート・タイプ | 形状 | 代表的なアプリケーション |
|---|---|---|
| シーエヌエムジー | ダイヤモンド | General turning, facing, and finishing |
| TNMG | トライアングル | Medium to heavy cutting, general purpose |
| SNMG | 正方形 | Roughing, interrupted cuts, heavy-duty applications |
| ブイエヌエムジー | V-Shaped | Finishing, profiling, and high-precision applications |
| WNMG | Hexagon | Medium to heavy roughing and interrupted cuts |
| シーシーエムティー | ダイヤモンド | Light to medium cutting, high precision, and finishing |
| ディーシーエムティー | ダイヤモンド | 仕上げと軽い切断 |
| SCMT | 正方形 | Medium to roughing, interrupted cuts, and heavy-duty applications |
| アールシーエムティー | ラウンド | Light to medium turning, profiling, and high-speed cutting |
| エーピーケーティー | 長方形 | Milling operations, high feed rates, and heavy-duty applications |
Applications of Carbide Tool Inserts
The versatility of carbide tool inserts makes them suitable for a wide range of applications. Here’s a table to present carbide tool insert applications:
| 産業 | 申し込み |
|---|---|
| 自動車 | Engine components, transmission parts, suspension systems |
| 航空宇宙 | Turbine blades, landing gear, structural components |
| メディカル | Surgical instruments, implants, prosthetics |
| 石油・ガス | Drill bits, casing, downhole tools |
| 製造業 | General machining, tool and die making, mold manufacturing |
| エレクトロニクス | Micro-machining, PCB manufacturing, semiconductor devices |
Material Properties of Carbide Tool Inserts
Understanding the material properties of carbide tool inserts is essential for selecting the right one for your application. Here’s a table to present material properties:
| プロパティ | 説明 |
|---|---|
| 硬度 | High resistance to wear and deformation, typically measured in Rockwell or Vickers |
| タフネス | Ability to absorb energy and resist chipping or fracturing |
| 耐熱性 | Retains hardness and strength at elevated temperatures |
| 化学的安定性 | Resistant to corrosion and chemical reactions with work materials |
| 熱伝導率 | Efficiently dissipates heat generated during cutting |
の組成と特徴 Carbide Tool Inserts
Carbide tool inserts are made from different grades of carbide, each offering unique characteristics. Here’s a table to present composition, properties, characteristics, etc.:
| グレード | 構成 | 特徴 |
|---|---|---|
| C1 | 97% WC, 3% Co | High wear resistance, used for non-ferrous materials |
| C2 | 94% WC、6% Co | Versatile, good for ferrous and non-ferrous materials |
| C3 | 90% WC、10% Co | Higher toughness, used for interrupted cuts |
| C4 | 86% WC、14% Co | Very tough, suitable for heavy-duty applications |
| C5 | 81% WC, 19% Co | Highest toughness, used for very heavy-duty applications |
| P10 | 92% WC, 8% Co, TiC/TaC additives | Good for high-speed finishing of steel |
| P20 | 89% WC, 11% Co, TiC/TaC additives | General purpose turning and milling of steel |
| P30 | 85% WC, 15% Co, TiC/TaC additives | Roughing and interrupted cuts in steel |
| K10 | 94% WC, 6% Co, Cr3C2/TaC additives | Finishing and semi-finishing of cast iron |
| K20 | 90% WC, 10% Co, Cr3C2/TaC additives | Roughing of cast iron and non-ferrous metals |
硬度、強度、耐摩耗性
Here’s a table to show hardness, strength, and wear resistance of carbide tool inserts:
| グレード | 硬度（HV） | 靭性（MPa） | 耐摩耗性 |
|---|---|---|---|
| C1 | 1800 | 1200 | 非常に高い |
| C2 | 1600 | 1500 | 高い |
| C3 | 1500 | 1800 | ミディアム |
| C4 | 1400 | 2200 | ミディアム |
| C5 | 1300 | 2500 | 低い |
| P10 | 1700 | 1400 | 高い |
| P20 | 1600 | 1600 | ミディアム |
| P30 | 1500 | 2000 | 低い |
| K10 | 1650 | 1300 | 高い |
| K20 | 1500 | 1800 | ミディアム |
仕様、サイズ、形状、規格
Carbide tool inserts are available in various specifications, sizes, and shapes. Here’s a table to show specifications, sizes, shape, standards:
| 形状 | サイズ(mm) | Thickness (mm) | ISO Standard | ANSI Standard |
|---|---|---|---|---|
| トライアングル | 12, 16, 20 | 3.97, 4.76, 6.35 | ISO 1832 | ANSI B212.4 |
| ダイヤモンド | 11, 13, 16 | 2.38, 3.18, 4.76 | ISO 1832 | ANSI B212.4 |
| 正方形 | 12, 16, 20 | 3.97, 4.76, 6.35 | ISO 1832 | ANSI B212.4 |
| ラウンド | 16, 20, 25 | 4.76, 6.35, 9.53 | ISO 1832 | ANSI B212.4 |
| 長方形 | 10, 15, 20 | 2.38, 3.97, 4.76 | ISO 1832 | ANSI B212.4 |
サプライヤーと価格詳細
Selecting the right supplier is crucial for ensuring the quality and performance of carbide tool inserts. Here’s a table with suppliers and pricing details:
| サプライヤー | 所在地 | 価格帯（米ドル） | 連絡先 |
|---|---|---|---|
| ケナメタル | アメリカ | 10-50 per insert | www.kennametal.com |
| サンドビック・コロマント | スウェーデン | 15-60 per insert | www.sandvik.coromant.com |
| イスカー | イスラエル | 12-55 per insert | www.iscar.com |
| セコ・ツールズ | スウェーデン | 13-58 per insert | www.secotools.com |
| 三菱 | 日本 | 14-60 per insert | www.mitsubishicarbide.com |
| 京セラ | 日本 | 10-45 per insert | www.kyocera.com |
| 住友 | 日本 | 11-50 per insert | www.sumitomotool.com |
| ウォルター・ツールズ | ドイツ | 13-55 per insert | www.walter-tools.com |
| タンガロイ | 日本 | 12-54 per insert | www.tungaloy.com |
| セラチジット | ルクセンブルク | 15-60 per insert | www.ceratizit.com |
正しい選び方 Carbide Tool Inserts
Choosing the right carbide tool insert involves considering several factors, including the material being machined, the type of machining operation, and the specific requirements of the job. Here’s a table to show how to select the right carbide tool inserts:
| ファクター | 考察 |
|---|---|
| 加工する材料 | Hardness, toughness, and abrasiveness of the material |
| 運営形態 | Turning, milling, drilling, finishing, roughing |
| 切断速度 | Higher speeds require inserts with better heat resistance |
| フィード・レート | Higher feed rates may require tougher inserts |
| 切り込み | Deeper cuts may require inserts with higher toughness |
| Machine Tool Capability | Power, rigidity, and speed of the machine tool |
| Surface Finish Required | Finishing operations may require inserts with finer grain structure |
| Tool Life Expectations | Longer tool life may justify higher initial cost |
の利点と限界を比較する Carbide Tool Inserts
Here’s a table comparing advantages and limitations of carbide tool inserts:
| メリット | 制限事項 |
|---|---|
| 高硬度 | Can be brittle, susceptible to chipping |
| 優れた耐摩耗性 | Higher cost compared to high-speed steel (HSS) |
| Ability to Maintain Cutting Edge | Limited toughness compared to ceramics |
| High Cutting Speeds | Requires precise handling and setup |
| Versatility in Applications | Specialized inserts needed for specific tasks |
よくあるご質問
What are carbide tool inserts used for?
Carbide tool inserts are used for cutting, shaping, and finishing various materials in machining operations such as turning, milling, and drilling.
Why are carbide inserts preferred over HSS tools?
Carbide inserts are preferred because they offer superior hardness, wear resistance, and the ability to maintain cutting performance at higher speeds and temperatures compared to high-speed steel (HSS) tools.
How do I choose the right carbide insert for my application?
Selecting the right carbide insert involves considering the material being machined, the type of machining operation, cutting speed, feed rate, and the required surface finish. Refer to the selection table provided above for detailed guidance.
What are the different grades of carbide inserts?
Carbide inserts come in various grades, each tailored for specific applications. For example, C1 is highly wear-resistant for non-ferrous materials, while P20 is a general-purpose grade for turning and milling steel.
超硬チップは再研磨できますか？
In most cases, carbide inserts are not resharpened. Instead, they are replaced once worn out or damaged, as resharpening can compromise their precision and performance.
超硬チップの寿命は？
The lifespan of carbide inserts depends on factors such as the material being machined, cutting conditions, and the type of operation. Proper selection and usage can maximize their longevity.
コーティングされた超硬チップを使用する利点は何ですか？
Coated carbide inserts offer additional benefits, including increased wear resistance, reduced friction, and extended tool life, particularly in high-speed and high-temperature applications.
Where can I buy carbide tool inserts?
Carbide tool inserts can be purchased from various suppliers such as Kennametal, Sandvik Coromant, Iscar, Seco Tools, and many others. Refer to the supplier table for more details.
Are there different shapes of carbide inserts?
Yes, carbide inserts come in different shapes like triangle, diamond, square, round, and rectangular, each suited for specific cutting tasks and applications.
What is the cost range for carbide inserts?
The cost of carbide inserts varies based on the supplier, grade, and specific type. Prices generally range from $10 to $60 per insert. Refer to the supplier pricing table for detailed information.
In conclusion, carbide tool inserts are essential for efficient and precise machining operations. By understanding their types, applications, properties, and how to select the right insert, you can optimize your machining processes and achieve superior results.
