Tool Inserts Improve Finish, Production Rate for High-Temp Alloys
Thinbit by Kaiser Tool Co. offers inserts tipped with cubic boron nitride and polycrystalline diamond.
Thinbit by Kaiser Tool Co. offers inserts tipped with cubic boron nitride (CBN) and polycrystalline diamond (PCD). CBN and PCD inserts are available for grooving, turning, face grooving, threading, boring and parting. The inserts are useful in form tools and custom geometries.
CBN-tipped inserts provide an increased production rate, improved surface finish and dimensional control when used on high-temperature alloys such as Inconel, nickel-based alloys and materials with a hardness of Rockwell C-35 or harder. PCD-tipped inserts provide these same benefits when used on nonferrous and abrasive metal such as aluminum, brass and copper.
The inserts fit L-series toolholders and can be used in conventional, Swiss-type and CNC machines. Toolholders are available in square shank sizes from 5/16" to 1¼" and round shank sizes from ½" to 1" with both straight and 90-degree presentations.
Applying ceramic inserts is not a simple substitution of one cutting tool material for another. There are significant process considerations that shops should examine carefully in order to realize performance and tool life expectations from ceramic inserts. Here's a look at some of the ways they are used.
One of the most common methods of tapping in use today on CNC machines is 'rigid tapping' or 'synchronous feed tapping.' A rigid tapping cycle synchronizes the machine spindle rotation and feed to match a specific thread pitch. Since the feed into the hole is synchronized, in theory a solid holder without any tension-compression can be used.
Running rotary milling cutters at the proper speeds and feeds is critical to obtaining long tool life and superior results, and a good place to start is with the manufacturer's recommendations. These formulas and tips provide useful guidelines.