概要 Tungsten Carbide Indexable Inserts
Tungsten carbide indexable inserts are a cornerstone in the world of machining. Whether you’re cutting, turning, milling, or boring, these tiny powerhouses are essential. They provide the durability and precision needed to tackle even the toughest materials. But what exactly are tungsten carbide indexable inserts, and why are they so crucial in modern machining?
In simple terms, these inserts are replaceable cutting tools made from tungsten carbide, a compound of tungsten and carbon known for its hardness and resistance to wear. These inserts are designed to be easily attached and detached from the tool holder, making them incredibly versatile and cost-effective. Let’s dive deeper into their types, applications, properties, and how to choose the right one for your needs.
Types of Tungsten Carbide Indexable Inserts
Understanding the various types of tungsten carbide indexable inserts is key to selecting the right one for your application. Here’s a table that categorizes these inserts based on their geometry and cutting purpose:
| インサート・タイプ | 形状 | 申し込み | 例 |
|---|---|---|---|
| 旋削インサート | 三角形 | General turning, profiling | TNMG, CNMG, DNMG |
| ミーリングインサート | 正方形 | Face milling, shoulder milling | APKT, SEKT, RDHT |
| ドリリングインサート | ラウンド | Drilling, boring | RCMX, SOMT |
| 溝入れインサート | Special | Grooving, parting | GTN, GCN, GRM |
| ねじ切りインサート | V-shaped | Internal and external threading | 16ER, 16IR, 11IR |
| Special Purpose Inserts | カスタム形状 | Tailored for specific applications | Custom inserts based on needs |
Notable Metal Powder Models
To get even more specific, let’s explore some metal powder models that are frequently used in the manufacture of these inserts:
- WC-6%Co (Tungsten Carbide with 6% Cobalt): Known for its toughness and resistance to thermal shock, suitable for roughing operations.
- WC-10%Co: Offers a good balance between hardness and toughness, ideal for general purpose machining.
- WC-12%Co: Provides higher toughness, often used in heavy-duty operations.
- WC-15%Co: Extremely tough, used for interrupted cutting and rough machining.
- TiC (Titanium Carbide): Enhances wear resistance, often added to improve performance at high cutting speeds.
- TaC (Tantalum Carbide): Used to increase hot hardness and wear resistance, typically for high-speed applications.
- NbC (Niobium Carbide): Improves toughness and resistance to deformation.
- VC (Vanadium Carbide): Adds to wear resistance and cutting edge stability.
- Cr3C2 (Chromium Carbide): Provides corrosion resistance and improved performance at elevated temperatures.
- Mixed Carbides: Combines different carbides to optimize properties for specific applications.
応用例 Tungsten Carbide Indexable Inserts
Tungsten carbide indexable inserts are versatile and find applications in various industries. Here’s a detailed table that outlines their primary uses:
| 産業 | 申し込み | 説明 |
|---|---|---|
| 自動車 | Engine components, transmission parts | High precision and durability for critical engine parts |
| 航空宇宙 | Structural components, turbine blades | High performance materials requiring excellent wear resistance |
| メディカル | 手術器具、インプラント | Biocompatible and precise machining for medical tools |
| 石油・ガス | 掘削装置、パイプライン部品 | Toughness and wear resistance for harsh drilling conditions |
| 建設 | Heavy machinery, tool bits | Durable and reliable for rough working environments |
| 一般製造業 | Tools, molds, dies | Versatile and cost-effective for everyday manufacturing needs |
Material Properties of Tungsten Carbide Indexable Inserts
The material properties of tungsten carbide inserts play a crucial role in their performance. Here’s a table highlighting some key properties:
| プロパティ | 説明 |
|---|---|
| 硬度 | Ranges between 85-92 HRA, ensuring cutting edge retention |
| タフネス | High fracture toughness to withstand heavy loads |
| 耐摩耗性 | Exceptional resistance to abrasion and wear |
| 熱伝導率 | Efficient heat dissipation to prevent overheating |
| 耐食性 | Resistant to oxidation and chemical reactions |
構成と特徴
The composition of tungsten carbide indexable inserts is a fine balance of different materials to optimize their performance. Here’s a table detailing their composition and characteristics:
| コンポーネント | パーセント | 特徴 |
|---|---|---|
| 炭化タングステン（WC） | 70-90% | 硬度と耐摩耗性を提供 |
| コバルト | 6-15% | Acts as a binder, enhances toughness |
| 炭化チタン（TiC） | 2-5% | Improves wear resistance and cutting performance |
| 炭化タンタル（TaC） | 1-3% | Increases hot hardness |
| その他の添加物 | 0.5-2% | Tailored to specific requirements (e.g., corrosion resistance) |
硬度、強度、耐摩耗性
Here’s a table showing the hardness, strength, and wear resistance of various tungsten carbide grades used in indexable inserts:
| グレード | 硬度（HRA） | 横方向の破断強度(MPa) | 耐摩耗性 |
|---|---|---|---|
| WC-6%Co | 89 | 2800 | 高い |
| WC-10%Co | 88 | 3000 | ミディアム-ハイ |
| WC-12%Co | 87 | 3200 | ミディアム |
| WC-15%Co | 85 | 3500 | ミディアム-ロー |
| Mixed Carbides | 90 | 2900 | 非常に高い |
仕様、サイズ、形状、規格
Tungsten carbide indexable inserts come in various specifications to suit different machining needs. Here’s a table summarizing these aspects:
| 仕様 | 詳細 |
|---|---|
| サイズ | Ranges from micro to large sizes for various tools |
| シェイプス | Triangular, square, round, diamond, custom shapes |
| 規格 | ISO、ANSI、DIN、JIS |
サプライヤーと価格詳細
Finding the right supplier is crucial for getting quality tungsten carbide inserts. Here’s a table listing some notable suppliers and pricing details:
| サプライヤー | 所在地 | 価格帯（1枚あたり） | ウェブサイト |
|---|---|---|---|
| サンドビック・コロマント | グローバル | $5 – $20 | www.sandvik.coromant.com |
| ケナメタル | USA, Global | $6 – $25 | www.kennametal.com |
| セコ・ツールズ | ヨーロッパ, グローバル | $7 – $22 | www.secotools.com |
| ISCAR | イスラエル, グローバル | $8 – $30 | www.iscar.com |
| 京セラ | 日本, グローバル | $5 – $18 | www.kyocera.com |
| 三菱マテリアル | 日本, グローバル | $6 – $20 | www.mitsubishicarbide.com |
How to Select the Right Tungsten Carbide Indexable Inserts
正しい選択 tungsten carbide indexable inserts can be tricky. Here’s a table to guide you through the key considerations:
| 考察 | 詳細 |
|---|---|
| 加工する材料 | Steel, aluminum, titanium, etc. |
| 機械加工 | Turning, milling, drilling, etc. |
| Insert Shape and Size | Depends on tool holder and application |
| コーティング | TiN, TiCN, Al2O3, depending on wear resistance needed |
| Cutting Speed and Feed Rate | Determines the insert grade and coating |
Advantages and Limitations of Tungsten Carbide Indexable Inserts
Here’s a comparative table of the advantages and limitations of tungsten carbide indexable inserts:
| アスペクト | メリット | 制限事項 |
|---|---|---|
| 耐久性 | Long-lasting due to high hardness and wear resistance | 強い衝撃を受けると脆くなることがある |
| 費用対効果 | Replaceable tips reduce overall tooling costs | Higher upfront cost compared to HSS tools |
| 汎用性 | Wide range of applications and materials | Requires careful selection for specific uses |
| 精密 | Maintains tight tolerances | Sensitive to improper handling |
よくあるご質問
What are tungsten carbide indexable inserts?
These are replaceable cutting tools made from tungsten carbide, used in various machining operations.
正しいインサートの選び方は？
Consider the material to be machined, the type of machining operation, and the desired finish.
Benefits of using tungsten carbide inserts?
They offer high hardness, wear resistance, and precision, making them ideal for various applications.
Can they be reused?
Yes, they can be re-sharpened and reused multiple times, adding to their cost-effectiveness.
What coatings are available for tungsten carbide inserts?
Common coatings include TiN, TiCN, and Al2O3, which enhance wear resistance and performance.
Are there different grades of tungsten carbide inserts?
Yes, different grades are available based on their composition, hardness, and toughness.
Where can I buy tungsten carbide inserts?
They can be purchased from various suppliers like Sandvik, Kennametal, Seco Tools, and more.
What industries use tungsten carbide inserts?
Automotive, aerospace, medical, oil & gas, construction, and general manufacturing.
結論
Tungsten carbide indexable inserts are indispensable in modern machining, providing unparalleled durability, precision, and versatility. By understanding the types, applications, material properties, and how to select the right insert, you can significantly enhance your machining efficiency and cost-effectiveness. Whether you are in the automotive, aerospace, or general manufacturing industry, these inserts are the go-to solution for your cutting needs.
