超硬チップ, also known as tungsten carbide inserts, are a critical component in the world of metalworking and machining. They are indispensable for their durability, efficiency, and versatility. If you’re diving into the world of machining or simply looking to upgrade your tooling arsenal, this guide will walk you through everything you need to know about cemented carbide inserts. From their types and applications to material properties and selecting the right one, let’s get started.
Overview of Cemented Carbide Inserts
Cemented carbide inserts are cutting tools used extensively in manufacturing and metalworking. They consist of a composite material made up of carbide particles bonded together by a metallic binder. This unique composition gives them superior hardness, wear resistance, and the ability to withstand high temperatures, making them ideal for cutting, drilling, and shaping metal materials.
Why Cemented Carbide?
- 耐久性がある： Cemented carbide inserts are incredibly durable and can withstand heavy usage.
- 効率が良い： They maintain sharpness and cutting efficiency over long periods.
- 汎用性がある： Suitable for a wide range of materials and machining operations.
種類 超硬インサート
There are various types of cemented carbide inserts designed for specific applications. Here’s a breakdown of some common types:
| インサート・タイプ | 説明 |
|---|---|
| シーエヌエムジー | General-purpose insert with 80° cutting edge, suitable for roughing and finishing. |
| DNMG | 55° cutting edge insert, ideal for finishing operations. |
| TNMG | Triangular insert, versatile for both roughing and finishing. |
| WNMG | Trigon shape with 80° cutting edge, used for roughing and interrupted cuts. |
| SNMG | Square insert, very strong, used for heavy-duty operations. |
| シーシーエムティー | Single-sided insert with 80° cutting edge, used for turning applications. |
| ブイビーエムティー | Diamond-shaped insert, used for fine finishing. |
| アールシーエムティー | Round insert, ideal for profiling and contouring. |
| エーピーケーティー | Rectangular insert, used for milling applications. |
| RPGN | Round insert, great for profiling soft materials. |
超硬インサートの用途
Cemented carbide inserts are used in a variety of machining operations. Here’s a look at their applications:
| 申し込み | Insert Types | 詳細 |
|---|---|---|
| ターニング | CNMG, DNMG, CCMT, VBMT | Turning operations involve rotating the workpiece while a stationary cutting tool removes material. |
| ミーリング | APKT, RPGN | Milling uses a rotating cutting tool to remove material from a workpiece in various directions. |
| 掘削 | WNMG, SNMG | Drilling operations create round holes in a workpiece using a rotating drill bit. |
| つまらない | CNMG, VBMT | Boring enlarges existing holes to achieve greater accuracy. |
| プロファイリング | RCMT, RPGN | Profiling operations create complex contours and shapes on a workpiece. |
| スレッディング | TNMG、VBMT | Threading inserts are used to cut screw threads into a workpiece. |
| グルーヴィング | SNMG, CCMT | Grooving involves cutting narrow channels into a workpiece. |
| 別れ | SNMG、WNMG | Parting operations cut off a section of a workpiece. |
| Face Milling | APKT, CCMT | Face milling uses a cutter to remove material from the surface of a workpiece to create a flat surface. |
| Interrupted Cutting | WNMG, SNMG | Inserts designed for interrupted cutting can withstand shocks and impacts from irregular cuts. |
材料特性 超硬インサート
Understanding the material properties of cemented carbide inserts is crucial for selecting the right one for your application.
| プロパティ | 説明 |
|---|---|
| 硬度 | Cemented carbide inserts are extremely hard, typically measuring 8.5-9 on the Mohs scale. |
| 耐摩耗性 | High resistance to wear, making them ideal for cutting and abrasive applications. |
| タフネス | Despite their hardness, they have sufficient toughness to withstand impact and shocks. |
| 耐熱性 | Able to maintain hardness and performance at high temperatures, often exceeding 1000°C. |
| 耐食性 | Resistant to corrosion, extending their lifespan in various environments. |
| 熱伝導率 | Good thermal conductivity helps in heat dissipation during cutting operations. |
| 密度 | High density, typically between 14.5-15.0 g/cm³. |
構成と特徴
The composition of cemented carbide inserts affects their properties and performance.
| コンポーネント | 説明 |
|---|---|
| 炭化タングステン | Main component, provides hardness and wear resistance. |
| コバルト | バインダーとして働き、強靭性と耐衝撃性を与える。 |
| 炭化チタン | Enhances hardness and thermal resistance, especially in high-speed cutting applications. |
| 炭化タンタル | Increases resistance to wear and deformation, especially at high temperatures. |
| 炭化ニオブ | Improves the grain structure, enhancing toughness and resistance to thermal shock. |
硬度、強度、耐摩耗性
These three properties are crucial in determining the suitability of a cemented carbide insert for a specific application.
| プロパティ | 説明 |
|---|---|
| 硬度 | Measured using the Rockwell or Vickers scales, indicating the material’s resistance to deformation. |
| 強さ | Indicates the material’s ability to withstand mechanical stress without breaking or deforming. |
| 耐摩耗性 | Refers to the material’s ability to resist wear and abrasion during cutting operations. |
仕様、サイズ、形状、規格
Cemented carbide inserts come in various sizes, shapes, and standards to meet different machining needs.
| 仕様 | 詳細 |
|---|---|
| ISO規格 | ISO 1832: Specifies dimensions and tolerances for carbide inserts. |
| シェイプス | Triangle, square, diamond, round, rectangular, trigon, etc. |
| サイズ | Available in various sizes to fit different tool holders and applications. |
| グレード | Different grades offer varying levels of hardness, toughness, and wear resistance. |
サプライヤーと価格詳細
Finding reliable suppliers and understanding pricing is crucial for making an informed purchase.
| サプライヤー | 地域 | 製品範囲 | 価格（概算） |
|---|---|---|---|
| ケナメタル | グローバル | Wide range of carbide inserts | $5 – $50 per insert |
| サンドビック・コロマント | グローバル | 高性能インサート | $10～$60（インサートあたり |
| 三菱マテリアル | グローバル | Various types and grades | $7 – $45 per insert |
| 住友電工 | グローバル | Advanced cutting tools | $8 – $55 per insert |
| ISCAR | グローバル | Innovative carbide inserts | $9 – $65 per insert |
| ウォルター・ツールズ | グローバル | Comprehensive range | $6～$40（インサートあたり |
| セコ・ツールズ | グローバル | High-precision inserts | $7 – $50 per insert |
| YG-1 | グローバル | Affordable, quality inserts | $5 – $35 per insert |
| タンガロイ | グローバル | Advanced material inserts | $10 – $55 per insert |
| 京セラ | グローバル | High-durability inserts | $8～$50（インサートあたり |
正しい選択 超硬インサート
Choosing the right cemented carbide insert involves considering several factors.
| 考察 | 詳細 |
|---|---|
| 加工する材料 | Different materials require different insert properties. |
| Type of Machining | The type of operation (turning, milling, drilling) dictates the insert shape and properties needed. |
| 切断条件 | Speed, feed rate, and depth of cut are crucial factors. |
| ツールホルダー互換性 | Ensure the insert fits the tool holder being used. |
| コスト | Balance between cost and performance to meet budgetary constraints. |
利点と限界
Comparing the advantages and limitations of cemented carbide inserts helps in making an informed decision.
| アスペクト | メリット | 制限事項 |
|---|---|---|
| 硬度 | Extremely hard, maintaining sharpness over long periods. | Can be brittle and prone to chipping under improper use. |
| 耐摩耗性 | High wear resistance, reducing the need for frequent replacements. | May be more expensive compared to other materials. |
| 耐熱性 | Retains properties at high temperatures, suitable for high-speed operations. | Requires precise cooling and lubrication to avoid thermal damage. |
| 汎用性 | Suitable for a wide range of materials and applications. | Specific inserts needed for different applications, adding to inventory complexity. |
| 耐久性 | Long lifespan, reducing downtime and increasing productivity. | High initial cost may be a consideration for some users. |
よくあるご質問
What are cemented carbide inserts used for?
Cemented carbide inserts are used in various machining operations such as turning, milling, drilling, and boring. They are preferred for their hardness, wear resistance, and ability to maintain performance at high temperatures.
How do I choose the right carbide insert for my application?
Selecting the right carbide insert involves considering the material to be machined, the type of machining operation, cutting conditions, tool holder compatibility, and cost.
What are the benefits of using cemented carbide inserts?
The main benefits include high hardness, excellent wear resistance, heat resistance, versatility, and durability. These properties result in increased productivity and longer tool life.
超硬チップは再利用できますか？
Yes, carbide inserts can often be reused after re-sharpening. However, the extent of reuse depends on the insert’s condition and the specific machining requirements.
What are the common grades of cemented carbide inserts?
Common grades include C2, C3, C5, and C7, each offering different levels of hardness, toughness, and wear resistance suitable for specific applications.
How should I store cemented carbide inserts?
Store them in a cool, dry place away from direct sunlight and moisture. Using appropriate storage containers can help prevent damage and maintain their quality.
Are there any environmental considerations with carbide inserts?
Cemented carbide inserts are made from materials that can be recycled. It’s important to follow proper recycling practices to minimize environmental impact.
What are some common brands of cemented carbide inserts?
Some popular brands include Kennametal, Sandvik Coromant, Mitsubishi Materials, Sumitomo Electric, ISCAR, Walter Tools, Seco Tools, YG-1, Tungaloy, and Kyocera.
How do carbide inserts compare to other cutting tools?
Compared to other cutting tools, carbide inserts offer superior hardness, wear resistance, and heat resistance. They are more durable and efficient but may come at a higher initial cost.
What is the average lifespan of a carbide insert?
The lifespan varies depending on the application, material being machined, and cutting conditions. However, carbide inserts generally last longer than other cutting tools due to their durable properties.
結論
Cemented carbide inserts are a cornerstone of modern machining, offering unmatched durability, efficiency, and versatility. Whether you’re a seasoned professional or just starting in the world of machining, understanding the types, applications, material properties, and selection criteria for carbide inserts can significantly impact your productivity and machining success.
By choosing the right carbide insert, you can enhance your machining operations, reduce downtime, and achieve superior results. Explore the various options, understand your specific needs, and make informed decisions to leverage the full potential of cemented carbide inserts in your projects.
