概要 超硬刃先交換式旋削インサート
Indexable carbide turning inserts are pivotal tools in the machining industry. These small but powerful components revolutionize metal cutting, offering versatility, efficiency, and precision. Whether you’re a seasoned machinist or just stepping into the world of metalworking, understanding these inserts can significantly enhance your machining capabilities.
What Are Indexable Carbide Turning Inserts?
At their core, indexable carbide turning inserts are cutting tools made from carbide material. These inserts can be indexed, meaning they can be rotated or flipped to use a fresh cutting edge, thus extending their lifespan. They come in various shapes, sizes, and grades, each designed for specific applications and materials.
Why Choose Indexable Carbide Turning Inserts?
- 効率性: These inserts reduce downtime by eliminating the need for frequent tool changes.
- 費用対効果: With multiple cutting edges, they offer better value over time.
- 精密: High accuracy in cutting leads to superior finishes.
- 汎用性: Suitable for a range of materials from aluminum to hardened steel.
種類 超硬刃先交換式旋削インサート
| インサート・タイプ | 説明 | 申し込み |
|---|---|---|
| シーエヌエムジー | Double-sided insert, versatile for roughing and finishing. | Steel, stainless steel, and cast iron. |
| DNMG | Diamond-shaped, ideal for profiling and finishing. | Hardened steels and superalloys. |
| TNMG | Triangular insert, strong cutting edges for heavy-duty cutting. | Roughing and medium turning. |
| ブイエヌエムジー | V-shaped insert, excellent for profiling and fine finishing. | Stainless steel and high-temperature alloys. |
| WNMG | Trigon-shaped, offers multiple cutting edges for efficient use. | General purpose turning, from roughing to finishing. |
| SNMG | Square insert, robust and suitable for heavy roughing. | Cast iron and non-ferrous materials. |
| CCGT | Positive rake, sharp edge for low cutting forces. | Aluminum and other non-ferrous metals. |
| SCMT | Square, single-sided, and strong insert for tough operations. | Steel and stainless steel. |
| TPGT | Positive rake, ideal for high-speed turning. | Soft materials like brass and aluminum. |
| RCGX | Round insert, ideal for high-feed turning and contouring. | Complex contours and high-feed rates. |
Applications of Indexable Carbide Turning Inserts
| 素材 | Suitable Insert Types | Application Description |
|---|---|---|
| スチール | CNMG, TNMG, SCMT | General turning, roughing, and finishing operations. |
| ステンレス鋼 | VNMG, DNMG, SCMT | Precision turning, profiling, and fine finishing. |
| 鋳鉄 | SNMG, CNMG, WNMG | Heavy-duty roughing and medium finishing. |
| Aluminum | CCGT, TPGT, RCGX | High-speed turning, low cutting force applications. |
| Superalloys | VNMG, DNMG, WNMG | High-precision turning, dealing with heat-resistant and tough materials. |
| Non-Ferrous Metals | CCGT, TPGT | Efficient turning with minimal tool wear. |
| 硬化鋼 | DNMG, VNMG | Hard turning, maintaining precision and surface finish. |
材料特性 超硬刃先交換式旋削インサート
| プロパティ | 説明 |
|---|---|
| 硬度 | Extremely hard, ensuring high wear resistance and long tool life. |
| タフネス | Capable of withstanding significant mechanical stress and impacts. |
| 耐熱性 | Maintains integrity and performance at high cutting temperatures. |
| Edge Sharpness | Precision-ground edges for accurate and smooth cutting. |
| 化学的安定性 | Resistant to chemical reactions, reducing tool wear and oxidation. |
組成、特性、特徴
| 素材 | 構成 | プロパティ | 特徴 |
|---|---|---|---|
| カーバイド | Tungsten Carbide + Cobalt Binder | 高硬度、耐摩耗性 | Suitable for various cutting conditions. |
| セラミックス | Aluminum Oxide + Silicon Carbide | Extremely hard, brittle | Ideal for high-speed cutting of hard materials. |
| サーメット | Ceramic + Metallic Binder | 高温安定性 | Excellent for finishing applications. |
| PCBN | Polycrystalline Cubic Boron Nitride | Extreme hardness, thermal stability | Used for hard turning applications. |
| ダイヤモンド | Pure Carbon Structure | Highest hardness, thermal conductivity | Best for non-ferrous metals and abrasive materials. |
硬度、強度、耐摩耗性
| インサート・タイプ | 硬度（HV） | 強度 (MPa) | 耐摩耗性 |
|---|---|---|---|
| カーバイド | 1500-2000 | 1500-2500 | 高い |
| セラミック | 1800-2400 | 500-800 | 非常に高い |
| サーメット | 1400-1600 | 1200-2000 | 高い |
| PCBN | 3000-4000 | 600-900 | エクストリーム |
| ダイヤモンド | 8000-10000 | 900-1200 | Ultimate |
仕様、サイズ、形状、規格
| 仕様 | サイズ | シェイプス | 規格 |
|---|---|---|---|
| 国際標準化機構 | 04, 08, 12, 16, 20 | トライアングル、スクエア、ラウンド | ISO 1832 |
| べいこくきかくきょうかい | 1/4″, 3/8″, 1/2″ | Diamond, Trigon, Rectangle | ANSI B212.4 |
| 日本工業規格 | 6mm、8mm、10mm | V-Shaped, Octagon | JIS B 4051 |
| DIN | 4mm, 6mm, 12mm | Hexagon, Pentagonal | DIN 4982 |
| カスタム | 変動あり | Custom shapes available | Custom standards |
サプライヤーと価格詳細
| サプライヤー | インサート・タイプ | 価格帯 | Additional Features |
|---|---|---|---|
| サンドビック | 全種類 | $5 – $25 per insert | Wide range, high quality, reliable. |
| ケナメタル | 全種類 | $4 – $22 per insert | Innovative designs, durable. |
| ISCAR | 全種類 | $6 – $28 per insert | Advanced technology, efficient performance. |
| 京セラ | 全種類 | $5～$20（インサートあたり | Cost-effective, versatile. |
| 住友 | 全種類 | $7 – $30 per insert | High precision, excellent finish. |
正しい選び方 超硬刃先交換式旋削インサート
| 基準 | 考察 |
|---|---|
| 素材 | Match insert material to workpiece material for optimal results. |
| Operation Type | Choose based on roughing, finishing, or profiling needs. |
| マシン能力 | Ensure the insert is compatible with your machine’s power and speed. |
| 切断速度 | Select inserts that can handle the desired cutting speed. |
| コスト | Balance between initial cost and long-term value. |
利点と限界
| メリット | 制限 |
|---|---|
| High precision and excellent finish | Initial cost can be high. |
| 複数のカッティングエッジ | Requires proper handling and setup. |
| Durable and long-lasting | Not all inserts are suitable for all materials. |
| 様々な用途に対応 | Specific inserts needed for specific tasks. |
Detailed Descriptions of Specific Metal Powder Models
- CNMG 432
- 説明: Double-sided with 80-degree cutting edge.
- 申し込み: General turning, both roughing and finishing.
- Material Compatibility: Steel, stainless steel, and cast iron.
- DNMG 441
- 説明: Diamond-shaped, perfect for fine finishing.
- 申し込み: Precision turning and profiling.
- Material Compatibility: Hardened steels and superalloys.
- TNMG 160408
- 説明: Triangular insert with robust edges.
- 申し込み: Heavy-duty roughing. Material Compatibility: Various steels and cast irons.
- VNMG 160404
- 説明: V-shaped insert for intricate profiling.
- 申し込み: Fine finishing.
- Material Compatibility: Stainless steel and high-temperature alloys.
- WNMG 080408
- 説明: Trigon shape with multiple edges.
- 申し込み: Versatile, from roughing to finishing.
- Material Compatibility: General purpose.
- SNMG 120408
- 説明: Square insert with strong edges.
- 申し込み: Heavy-duty turning.
- Material Compatibility: Cast iron and non-ferrous materials.
- CCGT 09T308
- 説明: Positive rake with sharp edge.
- 申し込み: High-speed turning.
- Material Compatibility: Aluminum and non-ferrous metals.
- SCMT 120408
- 説明: Square and single-sided.
- 申し込み: Tough operations.
- Material Compatibility: Steel and stainless steel.
- TPGT 110308
- 説明: Positive rake for smooth cutting.
- 申し込み: High-speed, precision turning.
- Material Compatibility: Soft materials like brass and aluminum.
- RCGX 120700
- 説明: Round insert for high-feed turning.
- 申し込み: Complex contours and high-feed rates.
- Material Compatibility: Various metals, especially for contouring.
よくあるご質問
| 質問 | 回答 |
|---|---|
| What are indexable carbide turning inserts? | These are cutting tools made from carbide material, designed to be rotated or indexed to use fresh cutting edges, extending their lifespan and efficiency. |
| Why use carbide inserts over traditional tools? | Carbide inserts offer multiple cutting edges, high precision, longer tool life, and versatility in various applications, making them cost-effective and efficient. |
| How to choose the right carbide insert? | Consider the material to be machined, the type of operation (roughing, finishing), machine capabilities, desired cutting speed, and overall cost efficiency. |
| What materials can be machined with carbide inserts? | Carbide inserts can machine a wide range of materials including steel, stainless steel, cast iron, aluminum, superalloys, and non-ferrous metals. |
| How do I ensure the longevity of my inserts? | Proper handling, correct setup, using the right insert for the right material and operation, and maintaining optimal cutting conditions can ensure longer tool life. |
| Where can I buy quality carbide inserts? | Reputable suppliers like Sandvik, Kennametal, ISCAR, Kyocera, and Sumitomo offer a wide range of high-quality carbide inserts suitable for various applications. |
結論
Indexable carbide turning inserts are integral to modern machining, offering unparalleled efficiency, precision, and versatility. Understanding the different types, their applications, and how to select the right insert for your needs can dramatically enhance your machining operations. Whether you’re dealing with steel, aluminum, or superalloys, there’s an indexable carbide turning insert tailored to your needs. Invest in the right tools, and watch your machining efficiency soar!
