超硬旋盤インサートガイド

Overview of Carbide Lathe Inserts

Carbide lathe inserts are crucial components in metalworking, especially in precision machining and cutting applications. These inserts, made from various grades of carbide, are designed to withstand high-speed operations, extreme temperatures, and the demands of repetitive machining tasks. Let’s dive deep into the world of carbide lathe inserts, explore their types, applications, material properties, and much more.

Types of Carbide Lathe Inserts

Carbide lathe inserts come in a variety of types, each suited for specific machining tasks and materials. Understanding these types is key to selecting the right insert for your needs.

インサート・タイプ説明
CNGPCNGP inserts are double-sided with a positive rake angle, ideal for light finishing operations.
DNMGDNMG inserts feature a 55-degree diamond shape, versatile for both finishing and roughing applications.
TNMGTNMG inserts have a triangular shape with a negative rake, perfect for heavy-duty cutting.
WNMGWNMG inserts are trigon-shaped, offering six cutting edges for increased efficiency in both roughing and finishing.
ブイエヌエムジーVNMG inserts are 35-degree diamond-shaped, excellent for profiling and finishing.
SNMGSNMG inserts are square-shaped, commonly used for general-purpose turning and facing.
アールシーエムティーRCMT inserts are round-shaped, providing smooth finishes and ideal for interrupted cuts.
SCMTSCMT inserts have a square shape with a positive rake, suitable for light to medium machining.
TCMTTCMT inserts are triangular with a positive rake, used for light-duty cutting and fine finishing.
シーシーエムティーCCMT inserts have a 7-degree relief angle, used for finishing and medium machining tasks.
carbide lathe inserts

Applications of Carbide Lathe Inserts

Carbide lathe inserts are used across various industries, from automotive to aerospace, owing to their durability and precision. Here’s a look at the typical applications.

申し込み説明
自動車Used for machining engine components, transmission parts, and other critical automotive parts.
航空宇宙Essential for manufacturing aircraft components, ensuring precision and durability.
医療機器Used in producing high-precision medical instruments and implants.
石油・ガスEmployed in the production of drilling equipment and pipeline components.
一般エンジニアリングSuitable for a wide range of engineering applications, from small machine parts to large industrial equipment.
金型Ideal for creating molds and dies due to their high wear resistance and precision.
発電Used in the manufacturing of turbines and other power generation equipment.
重機Essential for producing components used in heavy machinery and construction equipment.
RailwayUtilized in the production of railway components, ensuring longevity and reliability.
エレクトロニクスUsed for machining parts for electronic devices, requiring high precision and smooth finishes.

Material Properties of Carbide Lathe Inserts

Understanding the material properties of carbide lathe inserts helps in selecting the right insert for the job. Let’s explore the key properties.

プロパティ説明
硬度Carbide inserts are extremely hard, with a hardness typically around 90 HRA, making them suitable for cutting hard materials.
タフネスDespite their hardness, carbide inserts also offer good toughness, allowing them to resist chipping and breaking under high-stress conditions.
耐摩耗性High wear resistance ensures long tool life and consistent performance over extended use.
熱安定性Carbide inserts can withstand high temperatures generated during cutting, maintaining their hardness and performance.
化学的安定性Resistant to oxidation and other chemical reactions, ensuring durability in various working environments.
圧縮強度High compressive strength allows carbide inserts to handle heavy cutting loads without deformation.
熱伝導率Good thermal conductivity helps in dissipating heat quickly, reducing the risk of thermal damage to the workpiece and the insert itself.

Composition, Properties, and Characteristics of Carbide Lathe Inserts

The composition of carbide lathe inserts greatly influences their properties and performance. Here’s a breakdown of common compositions and their characteristics.

構成プロパティ特徴
炭化タングステン(WC)高硬度、耐摩耗性Most common material, excellent for a wide range of applications
コバルト(Co)バインダーAdds toughness to the insert, improves impact resistanceCommonly used as a binder with tungsten carbide for added toughness
炭化チタン(TiC)Enhances wear resistance, particularly at high temperaturesUsed in combination with WC for high-temperature applications
炭化タンタル(TaC)Improves hardness and thermal resistanceAdds strength and heat resistance, used in specialized applications
炭化ニオブ (NbC)Increases hardness and corrosion resistanceUsed for specialized applications requiring high corrosion resistance
炭化クロム(CrC)Provides excellent oxidation resistanceEnhances the performance in high-temperature and oxidizing environments
炭化バナジウム(VC)Increases wear resistance and toughnessUsed to improve overall durability and performance of the insert
Nickel (Ni) BinderEnhances corrosion resistance, adds toughnessUsed in applications where high corrosion resistance is required
Molybdenum Carbide (MoC)Adds hardness and thermal stabilityImproves wear resistance and performance at high temperatures
炭化ケイ素(SiC)Provides extreme hardness and high thermal conductivityUsed for cutting extremely hard materials like ceramics and hardened steels

硬度、強度、耐摩耗性

The performance of carbide lathe inserts is determined by their hardness, strength, and wear resistance. Here’s a detailed comparison.

パラメータ説明
硬度(HRA)Typically ranges from 85 to 93 HRA, ensuring the ability to cut through tough materials.
圧縮強度High compressive strength allows inserts to handle heavy loads without deforming.
耐摩耗性Exceptional wear resistance ensures long tool life and consistent performance over time.
タフネスBalances hardness with the ability to resist chipping and breaking under high-stress conditions.
熱安定性Maintains performance even at high temperatures generated during cutting.
耐薬品性Resistant to oxidation and other chemical reactions, ensuring durability in various environments.

仕様、サイズ、形状、規格

Carbide lathe inserts come in various specifications, sizes, shapes, and standards. Here’s an overview to help you choose the right insert.

仕様説明
ISO StandardInternational standards for insert shapes, sizes, and tolerances, ensuring compatibility and interchangeability.
ANSI StandardAmerican standards specifying insert dimensions, geometry, and application guidelines.
形状Common shapes include square (S), triangular (T), diamond (D), round (R), and trigon (W), each suited for different applications.
サイズSizes vary to fit different tool holders and accommodate various cutting depths and feed rates.
厚さThickness options ensure inserts can handle different cutting forces and provide desired rigidity.
コーナー半径Available in various radii to influence the finish and strength of the cutting edge.
コーティングInserts may have coatings like TiN, TiAlN, or CVD for enhanced wear resistance and performance.
チップブレーカーFeatures designed into the insert to control chip formation and evacuation, improving cutting efficiency.

サプライヤーと価格詳細

Several reputable suppliers provide high-quality carbide lathe inserts. Pricing varies based on the type, material, and quantity. Here’s a snapshot of some key suppliers and pricing details.

サプライヤー 製品範囲Average PricingWebsite
サンドビック・コロマントWide range of carbide inserts for various applications$10 – $50 per insertsandvik.coromant.com
ケナメタルHigh-performance carbide inserts for industrial use$15 – $60 per insert kennametal.com
セコ・ツールズVersatile inserts with advanced coatings and geometries$20 – $70 per insertsecotools.com
三菱マテリアル Innovative carbide inserts for various machining needs$12 – $55 per insertmitsubishicarbide.com
イスカーComprehensive range of carbide inserts for multiple industries$18 – $65 per insertiscar.com
住友電工High-quality inserts with advanced materials and coatings$15 – $60 per insertsumitomotool.com
TaegutecCost-effective carbide inserts with reliable performance$10 – $50 per inserttaegutec.com
ウォルター・ツールズDurable inserts for demanding machining operations$20 – $70 per insertwalter-tools.com
タンガロイVersatile and high-performance inserts for various applications$18 – $65 per insert tungaloy.com
京セラInnovative solutions with high-precision carbide inserts$15 – $55 per insertkyoceramicrotools.com

Selecting the Right Carbide Lathe Inserts

Choosing the right carbide lathe insert can significantly impact your machining efficiency and output quality. Here’s how to make the right choice.

ファクター考察
加工する材料Different materials require different insert properties. For example, hard steels need high wear resistance, while softer metals require high toughness.
機械加工Whether you’re roughing, finishing, or profiling, each operation has specific insert requirements for optimal performance.
インサート・ジオメトリーThe shape and edge geometry of the insert affect the cutting forces, chip control, and surface finish.
ツールホルダー互換性Ensure the insert fits your existing tool holders and machine setup.
切削パラメータConsider the cutting speed, feed rate, and depth of cut. Different inserts are designed to perform optimally under specific conditions.
コーティングCoated inserts offer enhanced wear resistance and performance in challenging environments.
コストBalance between the insert cost and its expected tool life and performance benefits.
サプライヤーの評判Choose suppliers known for quality and reliability to ensure consistent performance.

利点と限界を比較する

Different carbide lathe inserts offer various advantages and limitations. Understanding these can help you make an informed decision.

インサート・タイプメリット制限事項
CNGPExcellent for fine finishing, good chip controlLimited to light cutting applications
DNMGVersatile, suitable for both roughing and finishingMay not be optimal for very heavy cuts
TNMGDurable, handles heavy-duty cutting, multiple cutting edgesHigher cutting forces, may require more powerful machines
WNMGHigh efficiency with multiple cutting edges, suitable for a range of applicationsComplex geometry may lead to higher costs
ブイエヌエムジーIdeal for precision profiling and finishingLimited to lighter cuts, higher risk of breakage
SNMGGood for general-purpose use, strong cutting edgesLess efficient chip control compared to specialized inserts
アールシーエムティーProvides smooth finishes, handles interrupted cuts wellRound shape limits cutting depth and precision
SCMTSuitable for light to medium machining, good surface finishNot ideal for heavy cuts
TCMTExcellent for light-duty cutting, precise finishesLimited to lighter applications, higher risk of breakage
シーシーエムティーVersatile, good for both finishing and medium machiningMay not handle very heavy cuts effectively
carbide inserts for wood

よくあるご質問

What are carbide lathe inserts used for?

Carbide lathe inserts are used for precision machining tasks, including turning, facing, profiling, and finishing. They offer high wear resistance and can handle high-speed operations.

正しい超硬チップの選び方は?

Consider factors like the material to be machined, the type of operation, insert geometry, tool holder compatibility, cutting parameters, coating, cost, and supplier reputation.

What are the common types of carbide lathe inserts?

Common types include CNGP, DNMG, TNMG, WNMG, VNMG, SNMG, RCMT, SCMT, TCMT, and CCMT, each suited for specific applications and materials.

Why are carbide inserts preferred in machining?

Carbide inserts are preferred for their high hardness, wear resistance, toughness, and thermal stability, making them suitable for a wide range of machining tasks.

超硬チップの寿命は?

The lifespan of carbide inserts depends on factors like the material being machined, cutting parameters, and the type of insert. They generally offer a longer tool life compared to other materials.

超硬チップは再研磨できますか?

Some carbide inserts can be re-sharpened, but it’s often more cost-effective to replace them due to the precision required in the sharpening process.

What coatings are available for carbide inserts?

Common coatings include Titanium Nitride (TiN), Titanium Aluminum Nitride (TiAlN), and Chemical Vapor Deposition (CVD) coatings, enhancing wear resistance and performance.

Are there standards for carbide inserts?

Yes, there are ISO and ANSI standards that define the dimensions, geometry, and application guidelines for carbide inserts, ensuring compatibility and interchangeability.

Where can I buy carbide inserts?

Reputable suppliers like Sandvik Coromant, Kennametal, Seco Tools, Mitsubishi Materials, Iscar, Sumitomo Electric, Taegutec, Walter Tools, Tungaloy, and Kyocera offer high-quality carbide inserts.

What are the advantages of coated carbide inserts?

Coated carbide inserts offer enhanced wear resistance, longer tool life, better heat dissipation, and improved performance in challenging machining environments.

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