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.
Типы 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:
| Тип вставки | Форма | Типовые применения |
|---|---|---|
| CNMG | Алмаз | General turning, facing, and finishing |
| TNMG | Треугольник | Medium to heavy cutting, general purpose |
| SNMG | Квадрат | Roughing, interrupted cuts, heavy-duty applications |
| VNMG | V-Shaped | Finishing, profiling, and high-precision applications |
| WNMG | Hexagon | Medium to heavy roughing and interrupted cuts |
| CCMT | Алмаз | Light to medium cutting, high precision, and finishing |
| DCMT | Алмаз | Finishing and light cutting |
| SCMT | Квадрат | Medium to roughing, interrupted cuts, and heavy-duty applications |
| RCMT | Круглый | Light to medium turning, profiling, and high-speed cutting |
| APKT | Прямоугольная | 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:
| Промышленность | Приложение |
|---|---|
| Автомобильная промышленность | Engine components, transmission parts, suspension systems |
| Аэрокосмическая промышленность | Turbine blades, landing gear, structural components |
| Медицина | Surgical instruments, implants, prosthetics |
| Нефть и газ | Drill bits, casing, downhole tools |
| Производство | General machining, tool and die making, mold manufacturing |
| Электроника | 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:
| Недвижимость | Описание |
|---|---|
| Твердость | High resistance to wear and deformation, typically measured in Rockwell or Vickers |
| Жесткость | Ability to absorb energy and resist chipping or fracturing |
| Термостойкость | Retains hardness and strength at elevated temperatures |
| Химическая устойчивость | Resistant to corrosion and chemical reactions with work materials |
| Теплопроводность | Efficiently dissipates heat generated during cutting |
Состав и характеристики 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.:
| Класс | Состав | Характеристики |
|---|---|---|
| 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 |
Твердость, прочность и износостойкость
Here’s a table to show hardness, strength, and wear resistance of carbide tool inserts:
| Класс | Твердость (HV) | Жесткость (МПа) | Износостойкость |
|---|---|---|---|
| C1 | 1800 | 1200 | Очень высокий |
| C2 | 1600 | 1500 | Высокая |
| C3 | 1500 | 1800 | Средний |
| C4 | 1400 | 2200 | Средний |
| C5 | 1300 | 2500 | Низкий |
| P10 | 1700 | 1400 | Высокая |
| P20 | 1600 | 1600 | Средний |
| P30 | 1500 | 2000 | Низкий |
| K10 | 1650 | 1300 | Высокая |
| K20 | 1500 | 1800 | Средний |
Технические характеристики, размеры, форма, стандарты
Carbide tool inserts are available in various specifications, sizes, and shapes. Here’s a table to show specifications, sizes, shape, standards:
| Форма | Размер (мм) | Thickness (mm) | ISO Standard | ANSI Standard |
|---|---|---|---|---|
| Треугольник | 12, 16, 20 | 3.97, 4.76, 6.35 | ISO 1832 | ANSI B212.4 |
| Алмаз | 11, 13, 16 | 2.38, 3.18, 4.76 | ISO 1832 | ANSI B212.4 |
| Квадрат | 12, 16, 20 | 3.97, 4.76, 6.35 | ISO 1832 | ANSI B212.4 |
| Круглый | 16, 20, 25 | 4.76, 6.35, 9.53 | ISO 1832 | ANSI B212.4 |
| Прямоугольная | 10, 15, 20 | 2.38, 3.97, 4.76 | ISO 1832 | ANSI B212.4 |
Поставщики и ценовая политика
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:
| Поставщик | Расположение | Диапазон цен (USD) | Связаться с |
|---|---|---|---|
| Kennametal | США | 10-50 per insert | www.kennametal.com |
| Sandvik Coromant | Швеция | 15-60 per insert | www.sandvik.coromant.com |
| Искар | Израиль | 12-55 per insert | www.iscar.com |
| Инструменты Seco | Швеция | 13-58 per insert | www.secotools.com |
| Mitsubishi | Япония | 14-60 per insert | www.mitsubishicarbide.com |
| Kyocera | Япония | 10-45 per insert | www.kyocera.com |
| Sumitomo | Япония | 11-50 per insert | www.sumitomotool.com |
| Инструменты Walter | Германия | 13-55 per insert | www.walter-tools.com |
| Tungaloy | Япония | 12-54 per insert | www.tungaloy.com |
| Ceratizit | Люксембург | 15-60 per insert | www.ceratizit.com |
Как выбрать правильный 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:
| Фактор | Соображения |
|---|---|
| Обрабатываемый материал | Hardness, toughness, and abrasiveness of the material |
| Тип операции | Turning, milling, drilling, finishing, roughing |
| Скорость резки | Higher speeds require inserts with better heat resistance |
| Скорость подачи | Higher feed rates may require tougher inserts |
| Глубина среза | 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 |
Сравнение преимуществ и недостатков Carbide Tool Inserts
Here’s a table comparing advantages and limitations of carbide tool inserts:
| Преимущества | Ограничения |
|---|---|
| Высокая твердость | Can be brittle, susceptible to chipping |
| Отличная износостойкость | 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 |
ЧАСТО ЗАДАВАЕМЫЕ ВОПРОСЫ
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.
Можно ли перетачивать твердосплавные пластины?
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.
Каков срок службы твердосплавных пластин?
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.
Каковы преимущества использования твердосплавных пластин с покрытием?
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.
