DEEP HOLE DRILLING INSERTS,LATHE MACHINE CUTTING TOOLS,CARBIDE INSERTS

DEEP HOLE DRILLING INSERTS,LATHE MACHINE CUTTING TOOLS,CARBIDE INSERTS,We offer round, square, radius, and diamond shaped carbide inserts and cutters.

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How to Source High-Quality Carbide Inserts in Bulk

When it comes to sourcing high-quality carbide inserts in bulk, it's essential to conduct thorough research and make informed decisions to ensure that you receive products that meet your specific requirements and expectations. Carbide inserts are widely used in the metalworking industry due to their exceptional hardness, wear resistance, and precision. Here's a guide on how to source these inserts in bulk effectively.

1. Identify Your Needs

Before you start searching for suppliers, clearly define your needs. Determine the type of carbide insert you require, such as flat, indexable, or insertable carbide inserts. Consider factors like grade, coating, and dimensions. This information will help you narrow down your search and find suppliers that specialize in the specific inserts you need.

2. Research Potential Suppliers

Start by compiling a list of potential suppliers. Use online directories, industry forums, and trade shows to gather information about suppliers offering high-quality carbide inserts. Look for suppliers with a solid reputation, extensive experience, and a wide range of products.

3. Evaluate Supplier Reputation

Check the supplier's reputation by reading customer reviews, testimonials, and case studies. Look for feedback on their product quality, reliability, and customer service. A supplier with a strong track record and satisfied customers is more likely to provide high-quality carbide inserts.

4. Request Samples

Request samples from potential suppliers to evaluate the quality of their carbide inserts. This will give you a firsthand look at the product and help you determine if it meets your requirements. Pay attention to the insert's finish, hardness, and overall appearance.

5. Compare Prices and Terms

Compare the prices and terms offered by different suppliers. Be cautious of suppliers who offer unusually low prices, as this may indicate lower quality or unethical practices. Look for suppliers who offer competitive pricing, favorable payment terms, and bulk discounts.

6. Consider Lead Time and Shipping

When sourcing carbide inserts in bulk, consider the lead time and shipping options. Ensure that the supplier can meet your production schedule and provide reliable shipping methods. Look for suppliers with a good track record of on-time delivery.

7. Check for Certifications

Ensure that the supplier has the necessary certifications and quality control measures in place. Look for certifications such as ISO 9001, which demonstrates the supplier's commitment to quality management systems.

8. Establish a Long-Term Relationship

Once you've found a supplier that meets your requirements, consider establishing a long-term relationship. A strong partnership can lead to better pricing, improved customer service, and a more streamlined procurement process.

9. Maintain Communication

Keep open lines of communication with your supplier. Regularly discuss your needs, provide feedback, and address any concerns. This will help ensure that you continue to receive high-quality carbide inserts in bulk and that your supplier remains focused on meeting your requirements.

10. Stay Informed About Industry Trends

Stay informed about industry trends, advancements Carbide Milling Inserts in carbide insert technology, and new materials. This knowledge will help you make informed decisions when sourcing bulk inserts and Tungsten Carbide Inserts ensure that you remain competitive in the market.

In conclusion, sourcing high-quality carbide inserts in bulk requires careful planning, research, and evaluation. By following these steps, you can find a reliable supplier and ensure that you receive the products you need to meet your production demands.


The Cemented Carbide Blog: grooving inserts

How Do Lathe Cutting Inserts Perform When Machining Hard Materials

When it Carbide Inserts comes to machining hard materials, lathe cutting inserts play a crucial role in ensuring precision and efficiency. These cutting inserts are made from tough materials such as carbide, ceramic, or diamond coatings to withstand the high speeds and pressures involved in cutting hard materials like hardened steels, cast irons, or nickel-based alloys.

One of the main benefits of using lathe cutting inserts when machining hard materials is their superior hardness and wear resistance. Carbide inserts, for example, are extremely tough and can maintain their cutting edge even when exposed to high temperatures and abrasive materials. This allows them to cut through hard materials effortlessly and produce smooth finishes with minimal vibration or chatter.

Additionally, lathe cutting inserts come in a variety of different shapes and sizes to suit various cutting applications. Whether you are facing, turning, or grooving hard materials, there is a cutting insert designed to provide optimal performance and precision. The ability to quickly change out inserts also allows for increased productivity and reduced downtime during machining operations.

Furthermore, lathe Coated Inserts cutting inserts are designed with specific cutting angles and coatings to enhance chip evacuation and reduce cutting forces when machining hard materials. This results in longer tool life, improved surface finish, and overall cost savings in terms of reducing the need for frequent tool changes.

In conclusion, lathe cutting inserts are essential tools for machining hard materials due to their superior hardness, wear resistance, and specialized designs. By investing in high-quality cutting inserts and using them correctly, machinists can achieve precise and efficient machining of hard materials while maximizing tool life and productivity.


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Tungsten Carbide End Mill Tools Assortment

1. Tungsten carbide roughing end mills are used for removing large amounts of material in a quick, precise manner that allows for maximum efficiency and speed. Roughing end mills come in standard sizes both standard and metric from a few millimeters in diameter to more than an inch. Common standard sizes are .25, .5, .75 and 1 inch and available in fine and coarse tooth configurations. Most roughing end mills are made from cobalt, have three or more flutes and have coatings that dissipate heat to prolong their lives.

2. Tungsten carbide finishing Cemented Carbide Inserts end mills are used in computer numerical control and manual milling machines, as well as lathes of both kinds to bring the material to the finished dimensions as dictated by the blueprint. Finishing end mills come in all sizes with one-half inch the most common. They have between two and five flutes and can be made from various materials including high-speed steel and carbide. Other common sizes include 1 inch and specialty sizes are available as small as .05 inch.

3. Tungsten carbide ball end mills are specially made end mills with a ball end. They are perfectly suited for taking steps cuts of very small amounts of material. The radius of the end mill allows for small cuts using the tip that contours the area without interference of the 90-degree angles of standard end mills. Ball mills are finishing end mills and do not have ridged fluting. These end mills are often made of carbide for rigidity and can be coated to dissipate heat as well.

4. Tungsten carbide double ended end mills come in various sizes and variations including finishing and roughing types. There is a cutting edge on each side of the end mill, so it can be turned around once one edge becomes dulled. The standard sizes include .5, .75 and 1 inch for roughers and .5 inch for finishing end mills. Ball end mills are also available as double ended and come in standard .5 inch sizes.


Tungsten Manufacturer & Supplier: - https://www.estoolcarbide.com

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Anti-Electrolysis Developments In Wire EDM

These 100x magnifications of a 20-rms surface finish produced in identical CD650 workpiece materials show the difference between the effects of a standard power supply (left) and an AE power supply.

With a standard power supply on a wire EDM, stray energy from the cutting process (signified by the glowing light bulb) interacts with contaminants in the dielectric fluid, producing charged particles, shown in red, that attack the cutting edge as well as the top and bottom of the workpiece.

With an AE power supply on a wire EDM, stray energy from the cutting process is eliminated or controlled (signified by the unlit bulb), so there is little or no interaction with contaminants in the dielectric fluid. Particles, shown in white, do not attack the workpiece.

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These problems were intrinsic to the early days of EDMing and continued up through 1990. In 1991, the first compensating power supply circuitry was used for fine finishing on the skim cuts.

Previously, rough cutting was done with DC power for maximum speed and material removal. Fine or skim cutting was then done, at different power settings on an AC electrolysis-limiting power supply, to finish the dimension and, most often, to cover the damage done to the work-piece in roughing.

A true anti-electrolysis (AE) power supply can be used for rough and skim cutting, thus minimizing surface degradation, the material's susceptibility to rust and corrosive action, plus the overall improvements in accuracies and total time required to finish parts.

Since the mid-80s, literally all EDM manufacturers have addressed the finishing power supply issue, with various solutions offered. This is in sharp contrast to the "early" days of EDM's promotion, when speed, speed and more speed were the goals.

Briefly, let's get back to the basics of this critical aspect of EDMing.

What Is Electrolysis?

For the practical application of EDM, electrolysis is the production of chemical changes by the passage of an electrical current through an electrolyte, that is, a nonmetallic electrical conductor through which current is carried by the movement of agitated ions.

In wire EDMing, stray energy in the dielectric fluid, produced by the cutting process itself, interacts with contaminants in the flushing fluid to disrupt the surface of the workpiece.

The chief result of this process in all materials is an increased heat-affected zone, or white layer, on the surface. Depending upon the workpiece material being cut, the visible results of this action will vary, as described above.

The current-carrying EDM wire commonly discharges particles as well as produces the cutting action on the workpiece. The stray current, once thought inevitable, causes detrimental surface effects such as:

bluing of titanium,cobalt binder depletion of carbide,anodic oxidation of aluminum,rusting of ferrous materials, andeventual micro-cracking of all materials.

This last effect had prohibited increased use of wire EDMing in medical, aerospace, aircraft and ordnance applications because that condition would render parts either unsafe or inoperable to the specifications required.

Meeting The Challenge

Thus, the challenge facing EDM builders was to engineer a power supply that would minimize, even eliminate, the interaction of the stray current and contaminants on the workpiece surface. Various builders have taken various tacks to solving this problem. Mitsubishi EDM, for example, combined voltage modulation, advanced transistor pulse circuitry and state-of-the art sensors, plus software improvements to interface the cutting program and actual condition protocol, to develop its patented AE power supply. This combination of technologies indicates the complexity of the problem and the effort required to make progress in this area. However, the benefits are substantial--so substantial that this same builder has made its AE power supply standard equipment on its new X Generation wire EDMs.

Other methods are available, many of which have excellent characteristics, as they all aim at two important goals: namely, to eliminate or dramatically reduce surface degradation while, simultaneously, maintaining productivity on the machine.

Depending upon the EDM wire being used, brass or coated, surface finishes down to 0.5-mm Rmax are now attainable with no significant loss in speed. Doing certain types of wire work will always put a premium on an operator's work rate, and only the individual shop's particular needs can dictate the optimum conditions that should be employed.

However, unlike in the past, EDMers now enjoy more choices and thus fewer compromises when balancing speed versus accuracy and finish. To some extent, largely as the result of better power supplies and control circuitry, shops really can "have it all," or close to it.

The Differences AE Makes

Comparing the surface integrity achievable with and without an AE power supply makes it clear that several electrochemical conditions are occurring on an AE-equipped machine:

Pitting, which occurs with conventional power supply technology, is virtually gone.The heat-affected zone is drastically reduced.Surface corrosion is minimized on all materials.

The net effects of this AE power supply to the typical tool-and-die shop or mold maker are these:

Longer carbide tool life because of less cobalt depletion.Longer steel tool life because of less white layer and surface corrosion.Faster and fewer skim cuts needed to finish any part.Less polishing time and attendant cost because of less surface degradation and better finish out of the tank.

When used in conjunction with the Cemented Carbide Inserts fine finishing circuitry currently available, a true AE power supply can enable wire EDM to tackle the most demanding jobs, ones never thought possible. Clearly the evolution of EDM has been accelerated by the development of anti-electrolysis power supplies, another reason why wire EDM is now considered a viable method for an ever-widening spectrum of jobs in all areas of industry.

Click here to learn more about supplier MC Machinery Systems, Inc.. 

Reports From The Real World

One of the first builders to introduce anti-electrolysis (AE) technology, Mitsubishi EDM has had wire machines equipped with AE power supplies in the field long enough for interesting case histories to be gathered. A sample of these indicates the impact that AE technology will have on the typical EDM user.

Chris Shoulder Milling Inserts Gendusa, who runs the EDM operation at Custom Stamping in Covina, California, told his story. "The way we made punches and dies a few years ago seems to be on the decline. We do less and less grinding now. Instead, we use a wire EDM with the AE power supply and experience no recast whatsoever, plus all the micro-cracking problems we had are gone. Typically, we run a variety of micro-grain tungsten carbide, A2/D2 tool steels and some powdered metals. Thin steel frames are stacked and left in the tank for overnight cutting, maybe 18 up to 24 hours. We know the rust would be a problem with that kind of dwell time.

"Other advantages are in the taper and radius dimensioning, where we once needed to dress a grinding wheel and take a lot of time to do the work. All our die work goes to our company stamping plant in Carson City [Nevada], and we've already seen dramatic increases in wear life. We attribute most of that to the AE power supply on our wire EDM."

As for the speed of cutting when using an AE power supply, Pete Grisel of Magnum Diamond in Rapid City, South Dakota, said this: "We do high-precision parts for eye, medical, surgical and other equipment. Typically, we run titanium, stainless 317 and some aluminum. We'll stack our thinnest materials, 0.010-inch 440C stainless, 45 high and cut them in 35 minutes, with ¤0.002-inch accuracy, at 500 pieces per day. We also get a 7 to 8-rms, nearly mirror finish on a corneal shaper we produce." Magnum Diamond, a division of the Chiron Corp., has been running their AE power supply for over two years.

At EDM Labs in Fremont, California, Frank Wenzel runs an AE power supply on a wire EDM used to cut titanium 6AL-4V into an extremely delicate medical device component. "Titanium usually blues, and that problem simply went away with AE. Of course, it's not just cosmetics involved here. This power supply completely eliminated the embrittlement problem, and it's faster. We cut titanium faster with 0.008-inch diameter wire on an AE-equipped machine than we did with 0.01-inch wire before. Even on 50 pieces, that's a big difference."

Another job at EDM Labs involved a very tight cut into a 0.3-inch-high web of titanium material, using 0.004 wire. The part to be formed was 0.0013 inch thick, +0/-0.0003 inch, flat to within 0.0001 inch. "It simply would have been a nightmare to do this job before AE," according to Mr. Wenzel.

For shops where multiple part cutting was usually avoided due to rust build-up on conventional tool steels, no such concern is necessary with AE, reports indicate. Ejector pinholes, for example, can be machined into polished mold cavities without compromising the finish. Mold shops can actually use less expensive materials and get the same results. Less stainless is needed because of the rust avoidance issue. This means that less expensive S7 and H13 steel can be used for molds that are designed to be wire-cut instead of the more expensive 400 series.

At every stage of a technology's evolution, there are always roadblocks to its advancement. In the rapid development of EDM (electrical discharge machining), no hurdle has been more difficult to overcome than the one that is most basic to all machined metal surfaces in a liquid environment: Dissociation of ions caused by electric current passing through the solution, otherwise known as electrolysis or, in the common parlance, rust. Every metal subjected to EDMing is vulnerable to this condition, from the basic tool steels to the most advanced alloys and composite materials.

Electrical discharge machining, as the name implies, creates a certain amount of stray current in the dielectric fluid, by definition. Literally, the instant such current interacts with any contaminants in the solution, surface degradation on the workpiece begins.

Titanium will begin to turn blue, an action caused not by heat, as some suspect, but electrolysis. Aluminum undergoes an anodic oxidation. All iron-based materials simply begin to rust. Sintered materials such as carbides suffer surface degradation, the result of cobalt binder depletion.

 
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Redefining Plastics Manufacturing

Thogus, an injection molder in Avon Lake, Ohio, would have had no business calling on certain medical equipment manufacturers in the past. Now, things have changed.

For example, a company making CT scanners for hospitals and clinics might produce no more than hundreds of these machines per year. Many major components of these machines would be needed in similar small quantities. This is a problem for injection molding, which requires quantities that can justify mold tooling. As a result, Thogus would not have been a candidate for this work even if thermoplastic were the ideal material. The maker of the CT scanner would instead get its small quantity of parts through CNC machining in a metalworking shop.

Recently, however, Thogus expanded its capabilities. Along the way, it redefined the nature of its business. Thogus is still a plastics manufacturer, but today the company makes plastic parts through additive manufacturing in addition to injection molding. Specifically, it makes parts by directly printing them via fused deposition modeling (FDM) on equipment from Stratasys. The minimum viable order size when Thogus was limited to injection molding was tens of thousands of pieces. With additive manufacturing, the minimum viable order size is one piece. As a result of this change, the maker of CT scanners (an example that refers to a real Thogus customer) now has options beyond machining.

Product Development
Matt Hlavin is the president of Thogus. Pronounced “toh-gus,” the company name has a silent h (as does Hlavin’s last name). He says it was about 10 years ago that he started paying serious attention to equipment that builds plastic parts by fusing layers of material. Stratasys’ FDM process was particularly interesting to him, because this company’s machines build parts from materials comparable to those Thogus routinely molds. Thogus’ first FDM machine purchase was in early 2009, in the midst of the recession. Soon after it arrived, the machine let the molder impress a major prospect by delivering not only a proposal for a potential job, but also a ready prototype tool. Winning this job paid for the machine. Within a month, Thogus purchased its second FDM unit.

The machines are part of a larger strategy, Hlavin says. His company is no longer solely a manufacturer, no longer a company that serves customers just by making large runs of parts. The company is now a product development partner. “We are a black-box product development company that bolts right onto your business,” he says. The prototyping and short-run capability provided by additive manufacturing is one element of what makes this business model possible.

Another element is engineering staff. Thogus has been adding engineers at a Surface Milling Inserts faster rate than FDM machines. Chemical, mechanical, biomedical—the number of engineers on the payroll is now 15, about one-sixth of the company’s employees. In addition, half of the company’s 30 injection molding machines are now devoted to product development. Engineering staff plus additive manufacturing plus production capacity together now allow Thogus to carry a customer’s new part idea all the way from the initial concept to full-scale production.

The timing for such a business proved ideal. The recession that began in 2008 was different from the one that began in 2001, Hlavin says. Companies cut their in-house product development during that earlier recession, but later brought it back. They cut it again during this latest recession, but have not brought it back. Thogus fills a need that many Cermet Inserts companies can no longer fill internally.

Additive Applications
Now, the company owns five FDM machines across various sizes and models from Stratasys. The machines run in a special room that is devoted to additive processing. They are used to make not only short runs of production parts, but also short-run molds. A need for 50 pieces might be met by generating these parts directly, but a quantity of 500 or certainly 5,000 might instead be produced through injection molding with an FDM-generated tool. For a recent propylene part, an FDM mold that took only 15 hours to generate was able to deliver 15,000 pieces in the injection molding machines.

Thogus also keeps finding uses for additive manufacturing that serve its own operations. Clean and customized 5S shadowboards are now created this way. When injection molding operators were losing time looking for knockout bars, a rack for these bars was generated additively and bolted to the molding machine. And when a conveyor was modified so that small parts could be channeled into a small container beneath it, the necessary guide brackets were quickly created using FDM.

Perhaps the most significant use of additive manufacturing for Thogus’ internal needs is end-of-arm tooling for robotic loaders. Automation for the injection molding machines employs grippers or other tooling that is customized to the molded part. Thogus used to rely on an engineering firm and a machine shop to make this tooling. Now that the company has both the engineering talent and the additive capacity, it designs its own end-of-arm tooling, then produces it from components that are generated in the additive room.

Metal Molds
Hlavin says the next step for Thogus will be production metal molds created through additive manufacturing. The company has begun to experiment with mold tooling made through direct metal laser sintering. If the experience with this tooling continues to go well, he says he expects that Thogus will get its own direct metal laser sintering machine. Such a machine—perhaps complemented by just two CNC machine tools for completing the molds—would make it feasible for Thogus to realize its own in-house capacity to produce long-run mold tooling. By continuing to explore the possibilities of additive manufacturing in this way, Thogus continues to expand the scope of its own capabilities. 


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