Carbide Cutting Tool The Technology Control Is More And More Stable, Controllable And Reliable
The use of Carbide Cutting Tool can reap many advantages. Compared with high-speed steel tools, in most cases, the use of cemented carbide tool processing workpiece can not only obtain better machined surface quality, but also achieve a higher processing speed; cemented carbide cutters can withstand higher cutting heat, which is the main reason for the higher metal removal rate.
1. Carbide Blade Production
The production technology of indexable inserts is based on powder metallurgy technology, production process: cemented carbide mixture preparation, pressing, sintering, post treatment and coating. Although the basic processes have remained unchanged for decades, the progress of science and technology has had a significant impact on the manufacture of blades.
With more and more advanced industrial equipment with automation and computer control into cemented carbide manufacturing enterprises, the technical control of cemented carbide production process is more and more stable, controllable and reliable. The result is that the machining performance of the blades is becoming more and more consistent, the processing result is predictable and not because the blade batch number is different, the new technology also makes the size tolerance band of the sintered blade narrower and more accurate, and the performance of cemented carbide blades is greatly improved.
Today, a typical blade press is a computer-controlled, highly assembled engineering device. The design of some presses can also carry out multi-axis compression. Extraordinary advances from repressive technologies have made it possible to produce blades with complex shapes, such as blades with very large differences in the tip height (see fig. 1). Advanced pressing technology ensures that the blade shape can be harvested more optimally, not only to ensure smooth blade surface and stability of blade production process, but also to improve the precision level of blade surface. In addition, the application of modern computer aided design and manufacturing technology (CAD/CAM) has also brought benefits to the manufacture of blades, which makes it possible to improve blade design level and obtain better shape and precision of die parts. With the final sintering product as the guide to simulate the production process, the initial stage of the design can be modified from the design point of view of the suppression of sintering, in order to promote the successful development of new blades.
The control of advanced technology of Blade sintering also helps to improve the quality of blades in the process of production. During the sintering process, the process control is carried out to obtain the gradient cemented carbide matrix of non-uniform structure to ensure the cobalt-rich layer with thin layer on the alloy surface. The development of the physical strength of cemented carbide base with gradient layer blocks the surface crack, which ensures better crack resistance and breakage resistance of cemented carbide substrates. Today, graded cemented carbide substrates are often used in cutting tools for turning processes.
2. Development of coating technology
The introduction of coated cemented carbide and the continuous development in this field have greatly improved the cutting speed of the cutting tool. From the processing example, 30 years ago, the cutting speed of the ISCA non-coated cemented carbide grade IC20 turning gray Iron was about 100m/mi N; now, the cutting speed of ISCA coated cemented carbide grade IC5005 is 600m/min. In another case, in the same period, the cutting speed of ISCA ic50m milling martensitic Stainless steel was 80m/m i n; now the cutting speed of the coating grade IC5500 is 300m/min. These impressive data have fully interpreted the leaping development of coated cemented carbide for cutting speed of cutting tools.
The coating technology continues to evolve along two basic directions: chemical Vapor deposition coatings (CVD) and physical Vapor deposition coatings (PVD). The major development of CVD coatings comes from the introduction of alumina ceramic coatings. Alumina ceramic coating has excellent thermal insulation property, abrasion resistance and chemical stability at high temperature, which makes the tool can be processed at a higher cutting speed.