Connecting Design and Production

In a recent featured article Carbide Inserts in Fabricating & Metalworking magazine, our product manager Alan Miller discusses how creative and resourceful applications of tooling and accessories, such as angle heads, can get complex parts out the door instead of having to lose those parts due to design edits.

Alan mentions that “the power of modern design software and production machinery have manufacturers exploring the limits of what’s possible”. He further states that when these two sides struggle to meet in the middle, problems arise: you can draw pretty much anything you want, but that doesn’t necessarily make it something that can be manufactured efficiently, or at all, for that matter.

To expand on this statement, Alan shares how with the proliferation of multi-axis machinery, it was thought that an add-on accessory like an angle head would be rendered Carbide milling inserts obsolete. That hasn’t proven to be true as BIG KAISER has seen a great interest in this accessory, and today’s vigorous push and pull between design and manufacturing is likely a big reason.

In the article, Alan provides some reasons as to why a relatively simple-to-integrate and inexpensive accessory like an angle head can assist in finding the delicate balance between design and production needed to deliver profitably. The reasons explained include:

• The ability to add an additional axis to existing equipment
• The ability to use shorter tools
• Eliminating multiple setups
• Eliminating unnecessary equipment
• Access to complex internal features

The value of angle heads is magnified by the fact that they are available at almost any angle, fixed or adjustable, for use in high volume production or prototyping. They’re also easy to integrate. While highly specialized applications can take longer, most simple machines that are ready to accept a stop block can be up and running in less than half an hour.

To read the full article titled “How to Bridge the Gap Between Design and Production” and learn more about the reasons highlighted above, click?here.

The Tungsten Carbide Blog: http://allbest.blog.jp/

How To Choose The Right Carbide End Mill Type？

The public has more strict criteria on the end mills they buy because of the widespread usage of CNC machine tools. These needs include the milling cutters’ size, stiffness, accuracy, durability, strength, and stability. The selection of the appropriate carbide end mill is of utmost significance if one want to increase the effectiveness of the milling operation.

When choosing a carbide end mill, it is important to take into account how well the material cuts. It is advised, for instance, to use carbide end mills with improved wear resistance when working with work parts made of titanium alloy, high-strength steel, and stainless steel. These cutters can withstand more use.

What You Should Think About Before Getting an Carbide End Mill

End mills are purposefully designed tools, and each tip shape provides a different kind of clearing path that may be used in a variety of contexts. The nature of the project, the kind of material that has to be cut, and the surface quality that must be achieved all play a significant role in determining which end mill should be used. If you choose the improper cutting tool, you run the risk of swiftly damaging a work piece, which will force you to throw out the whole batch. This is not only a very inefficient use of your organization’s time but also a considerable financial burden.

If you are searching for the best carbide end mill type for the task, there are many considerations that need be made, but if you ask yourself these important questions as you go through the process, you will be more equipped to make the proper choice.

• Your decision will be heavily impacted by these three important considerations:
• What kinds of forms do you want the milling machine to make for you?
• Which kind of material will you be milling?

What are your objectives in terms of performance and surface polish, while ensuring that the cost remains within a range that is acceptable to you and remaining within the capabilities of your CNC machine?

Your answers to these questions will help you decide the appropriate tool geometry, which will depend on the sort of project you are working on, the material that is being cut, and the surface finish you want to achieve. So let’s get started on the theory, and if you have any questions along the way, I’ll address them with some actual instances afterwards.

Geometry of Carbide End Mills and Fundamental Concepts

The success of the tool is directly proportional to how carefully the end mill shape is selected. If you want to increase the likelihood that you will be successful with a particular tool, it is in your best interest to pay careful attention to the components that the maker of the instrument suggests using. The speeds and feeds that the manufacturer suggests using for that particular material are also very important.

Overall length

Let’s say you have a high component and you want to mill an extremely deep pocket within it. In order to mill the bottom of the material without your spindle mandrel meeting the stock of the material, you will require a long tool. Therefore, the depth Tungsten Steel Inserts of the cut that your end mill has to make into the material will define how long it needs to be. The term “stick out” is used to refer to the idea that is linked with this finding. The distance from the end of the tool holder to the tip of the end mill serves as the defining dimension for it.

Another thing to bear in mind is that the cutting depth of your end mill should never go beyond the length of the flutes. If you cut deeper than the length of the flutes on your tool, the chips won’t clear as they should, heat will build up, and you run the danger of damaging it.

At this point, it could seem to be a good idea to invest in end mills that are as long as physically feasible so that you have the ability to utilize them in a greater variety of settings, right. In fact, this is not the case since Carbide milling inserts the stick out of a tool contributes to its overall lack of rigidity. If you work it too hard and it sticks out too far, the cutting forces will cause it to bend, which is referred to as “tool deflection.” If it sticks out too far and you work it too hard, it will break.”

Carbide milling cutter

Select a milling cutter based on the parameters of the region to be treated. When processing thin-walled or ultra-thin-walled work pieces, the end edge of the over-center milling cutter should have an appropriate centripetal angle to lower the cutting force of the milling cutter and the cutting portion. When working with soft materials like aluminum and copper, utilize an end mill with a slightly greater rake angle, and keep the number of blades as low as feasible.

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When selecting a milling cutter, strive to match the milling cutter’s size to the surface size of the workpiece to be treated. Carbide end nd mills are usually utilized in production for the peripheral contour processing of flat workpieces; cemented carbide milling cutters are favored for milling planes; and high-speed steel end mills are favored for milling bosses and grooves. in manufacturing Corn cutters with carbide inserts are suggested for rough cutting the surface of the blank or hole; for certain three-dimensional profiles and changeable bevel contour contours, utilize ball end milling cutters, ring cutters, tapered milling cutters, and discs.

Helix angle

Helix angles of general-purpose end mills are normally around about 30 degrees. During the milling process, a reduction in the cutting forces, as well as a decrease in the quantity of heat and vibration, may be achieved by increasing the helix angle. Therefore, end mills that have a larger helix angle have the tendency to generate a superior surface finish on the workpiece they are used on.

Unfortuitously, it comes with a trade-off of some kind. The end mill will become less robust and will not be able to withstand heavy depths of cut when fed at high rates. Therefore, angle cutters with a lower helix are more robust, but the surfaces they cut leave a rougher finish.

Flute Count

Flutes are helical grooves that wrap around the sides of an end mill and give the tool its name. When chipping lengthy materials like aluminium, tools with a lesser number of flutes (two to three flutes) will provide greater area for the flutes themselves. A greater number of flutes results in a smaller flute spacing, but it may lead to improved productivity in materials that need shorter chipping, such as iron and steel with a medium to high carbon content. A four?flute endmill is?recommended for slotting applications when working with steel, stainless steel, high temperature alloys, and iron. This kind of endmill may also be an excellent general-purpose tool. Applications that have a shallow radial depth of cut are the best candidates for higher flute counts because they provide more room for chip evacuation.

Shapes ?and Types

• Stainless Steel End Mill Made

For each step of the work piece’s processing, we have the option of selecting a different kind of end mill made of stainless steel. For instance, during the rough machining step, our primary objective is to eliminate the margin. Once this objective has been accomplished, we may use a big milling cutter that has improved stiffness but lower accuracy and greater chip removal performance. During the phases of semi-finishing and finishing, the most important thing is to make certain that the machining precision and product quality are both satisfactory. At this point, you should choose a finishing milling cutter that has more endurance and greater precision than the one you are currently using.

• Ball Nose End Mills

Ball nose mills feature a radius at the bottom, which creates a finer surface finish in your workpiece. This results in less labor for you, since the item does not need to be finished any further once it has been created using a ball nose mill. Applications such as pocketing, shallow slotting, contouring, and milling contours are some of the uses for these tools. Because they are less likely to damage the material being worked on and provide a beautiful rounded edge, ball nose mills are an excellent choice for 3D contouring. After you have removed big portions of the material using a roughing end mill, continue on to the next step with a ball nose end mill.

• Square End Mills

Square end mills, which more often go by the name Flat End Mills, are used to create a sharp edge at the bottom of the slots and pockets that are cut into the workpiece. In addition to slotting, profiling, and plunge cutting, they are utilized for general milling applications.

• Corner Radius End Mills

Comparable to square end mills and flat end mills, but the cutting edge on them is round, earning them the nickname “bull nose” (not to be confused with Ball nose as mentioned above). They have a usually longer tool life and are less prone to chipping than other materials.

• Roughing End Mills

Roughing end mills are excellent for working with vast surface areas because they feature multiple serrations (teeth) in the flutes that enable them to rapidly remove huge quantities of material while leaving a rough finish. They are also known as Corn Cob cutters and Hog Mills, both of which get their names from the pig, which is said to “grind” away at, or eat, whatever that is in its path.

• The Materials Used In End Mills

This part may easily warrant its own essay, but in the interest of brevity, let’s discuss the two most common materials used in the production of cutting tools: high-speed steel and carbide.

High-Speed Steel, often known as HSS, has a lower cost than the other option, it has a good resistance to wear, and it can be milled into many other materials, including wood, metals, and plastics.

End mills made of coated carbide?are more costly than those made of high-speed steel (HSS), but they provide more stiffness and can be operated at speeds that are two to three times quicker than HSS. They are also very resistant to heat, which enables them to grind materials that are more resistant to abrasion.

If this is the case, are carbide end mills worth the additional cost? Yes, without a doubt.

They are able to operate far quicker than HSS, which means that they will significantly boost the productivity of your machine. The fact that they are also more durable and have a longer tool life makes the initial financial outlay worthwhile.

Including a quality coating on your end mills is an additional simple method that may improve their performance. TiAlN (titanium aluminium nitride), the most popular one, will enable you to cut 25 percent quicker on average without requiring an excessive amount of additional financial investment.

If performance is not a primary concern of yours, then you should go for carbide end mills that have a diameter of 8 millimeters or less. When the tool stiffness can be compensated for by its greater diameter, HSS should be considered for bigger cutters since it may save you some money. In addition, if you are just starting out with CNC milling, keep in mind that you will likely make some errors and damage a few end mills before you get the hang of things. Therefore, you should invest in some superior HSS ones as well.

Conclusion

Carbide end mills provide you a great deal of flexibility in terms of the machining tasks you may do. We hope that by reading this post, you will have a better understanding of the many kinds and the uses for each. No matter the task, Huana is pleased to provide a comprehensive selection of carbide end mills that are developed to provide you with an advantage over other businesses in your industry. Huana is ready to assist you with any issues you may have about the selection of the appropriate end mills or other cutting equipment for your business. Simply ask any questions you have about end mills, and we will do our best to answer them.

The Tungsten Carbide Blog: https://jeromelind.exblog.jp/

Detection of salt spray corrosion of metallic materials

1 IntroductionCorrosion to metal materials caused by the huge loss of huge. Some people count the annual corrosion of scrap metal around 100 million tons, accounting for 20% to 40% of annual production. And with the process of industrialization, corrosion problems become more serious, the United States in 1949 corrosion consumption (material consumption and corrosion) to 50 billion US dollars, 1975, 70 billion US dollars, to 1985 as high as 168 billion US dollars, compared with 1949 increased More than 80 times. It is estimated that the world’s annual scrap due to corrosion of steel equipment equivalent to 30% of annual production. Obviously, the destruction of metal components, its value is much greater than the value of metal materials; developed countries each year due to corrosion caused by economic losses accounted for about 2% to 4% of the gross national product; the United States each year due to corrosion to consume 3.4% Of the energy; China’s annual economic losses caused by corrosion at least 20 billion. The great harm of corrosion is not only reflected in the economic loss, it will bring heavy casualties, environmental pollution, waste of resources, hinder the development of new technologies to promote the loss of natural resources.2 salt spray corrosion background and mechanismCorrosion is damage or deterioration caused by the material or its properties under the action of the environment. Most of the corrosion occurs in the atmosphere, the atmosphere contains oxygen, humidity, temperature changes and pollutants and other corrosive factors and corrosion factors.Salt spray corrosion is a common and most damaging atmospheric corrosion. Where salt spray refers to the atmosphere of chloride, its main corrosion component is sodium chloride. Salt mist corrosion of the surface of the metal material is due to chloride ions penetrate the metal surface of the oxide layer and the protective layer and the internal metal electrochemical reaction caused. At the same time, the chloride ion contains a certain hydration energy, easily adsorbed on the surface of the metal pores, cracks and replace the chlorinated layer of oxygen, the insoluble oxide into soluble chloride, the passive surface becomes lively Surface, resulting in a very bad product adverse reactions.Anode: The metal loses electrons into metal cations and enters the solution in the form of hydrated ions while leaving considerable electrons in the metal.Me + nH2O → Me2 + · nH2O + 2e-Cathode: the remaining electrons remaining in the cathode metal, depolarized by oxygen, to restore and absorb electrons, to become hydroxide ions.O2 + nH2O + 4e- → 4OH-Electrolyte: sodium chloride dissociation and the formation of sodium ions and chloride ions, part of the chloride ions, metal ions and hydroxide ions into a metal corrosion.2Me2 ++ 2Cl- + 2OH- → MeCl2 Me (OH) 23 salt spray corrosion hazards1) salt spray corrosion will destroy the metal protective layer, it lost decorative, reduce the mechanical strength;2) some electronic components and electrical lines, due to corrosion caused by power line interruption, especially in a vibrating environment, especially serious;3) When the salt spray falls on the insulator surface, the surface resistance will be reduced; the insulator absorbs the salt solution, its volume resistance will be reduced by four orders of magnitude;4) The moving parts of the mechanical parts or moving parts are increased in friction due to the generation of corrosive substances and cause the moving parts to be stuck.4 metal salt spray test testSalt spray test is divided into natural environmental exposure test and artificial acceleration simulation environment test, the latter is the use of salt spray chamber, in its volume space with artificial methods to create salt spray environment to the product of salt spray corrosion performance quality Assessment.Compared with the natural environment, the salt concentration of chloride salt environment, can be the general natural salt spray content of several times or several times, so that the corrosion rate greatly improved, the product salt spray test, the results of the Time is greatly shortened. If a sample is tested in a natural exposure environment, it may take one year to be corroded and a similar result can be obtained for 24 hours in the simulated salt spray environment. But the artificial acceleration simulation test is still different from the natural environment, and therefore can not be replaced.4.1 Test equipment4.2 Scope of application1) steel surface copper + nickel + chromium or nickel + chromium;2) copper or copper alloy surface nickel + chromium;3) 300 series or 400 series stainless steel surface nickel + chromium;4) aluminum or aluminum alloy surface copper + nickel + chromium;5) zinc alloy surface copper + nickel + chromium;6) plastic plating parts.4.3 Test methods4.3.1 Neutral Salt Spray Test (NSS Test)Is the earliest widely used in the field of accelerated corrosion test method. It uses 5% sodium chloride solution, the solution PH value adjusted in the neutral range (6 ~ 7) as a spray solution. The test temperature is 35 ℃, requiring the sedimentation rate of salt spray between 1 ~ 2ml / 80cm · h.4.3.2 Acetate spray test (ASS test)Is based on the neutral salt spray test developed on the basis of. It is in 5% sodium chloride solution by adding some glacial acetic acid, the solution of the PH value is reduced to about 3, the solution becomes acidic, and finally the formation of salt mist from neutral salt mist into acidic. Its corrosion rate is about 3 times faster than the NSS test.4.3.3 Copper Salt Accelerated Acetate Fog Test (LRHS-663P-RY)Is a newly developed abroad, a rapid salt spray corrosion test, the test temperature of 50 ℃, salt solution by adding a small amount of copper salt – copper chloride, strongly induced corrosion. Its corrosion rate is about 8 times the NSS test.4.3.4 alternating salt spray testIs a comprehensive salt spray test, which is actually a neutral salt spray test plus a constant damp heat test. It is mainly used for cavity-type machine products, through the tidal environment of the infiltration, so that salt spray corrosion not only in the product surface, but also within the product. It is the product in the salt spray and hot and humid two environmental conditions under the alternating conversion, the final assessment of the whole product of electrical properties and mechanical properties have changed.4.4 Influencing factorsThe main factors influencing the results of salt spray test include: temperature and humidity of test, concentration of salt solution, sample placement angle, pH value of salt solution, salt spray settlement and spray method.1) Test temperature and humidityTemperature and relative humidity affect the corrosion of salt spray. The critical relative humidity of metal corrosion is about 70%. When the relative humidity reaches or exceeds this critical humidity, the salt will deliquescence and form an electrolyte with good electrical conductivity. When the relative humidity is reduced, the salt solution concentration will increase until the precipitation of crystallization salt, corrosion rate correspondingly reduced. The higher the test temperature, the faster the salt spray corrosion rate. For the neutral salt spray test, most scholars believe that the test temperature is more appropriate at 35 ℃.2) the concentration of salt solutionThe effect of the concentration of the salt solution on the corrosion rate is related to the type of material and coating. When the concentration is more than 5%, the corrosion rate of these metals decreases with the increase of the concentration. When the concentration is more than 5%, the corrosion rate of these metals decreases with the increase of the concentration.3) the placement angle of the sampleThe placement angle of the sample has a significant effect on the results of the salt spray test. Salt sedimentation direction is close to the vertical direction, the sample placed horizontally, it has the largest projection area, the sample surface to withstand the maximum amount of salt spray, so the most serious corrosion. GB / T2423.17-93 standard “flat plate sample placement method, the test surface should be made with the vertical direction of 30 degrees.4) the pH of the salt solutionThe pH value of the salt solution is one of the main factors affecting the salt spray test results. The lower the pH value, the higher the concentration of hydrogen ions in the solution, the stronger the acidity and the stronger the corrosivity. The salt spray test of Fe / Zn, Fe / Cd, Fe / Cu / Ni / Cr and other electroplating parts showed that the corrosion rate of the salt solution was higher than that of the pH value of 3.0, 7.2 neutral Carbide Milling Inserts salt spray test (NSS) harsh 1.5 to 2.0 times.5) salt spray settlement and spray method6) the duration of the test4.5 Determination of resultsThe purpose of the salt spray test is to assess the quality of the salt spray resistance of the product or metal material, and the salt spray test result is the judgment of the quality of the product. Whether the judgment result is correct or not is the correct measurement of the product or metal salt spray The key to corrosion quality. The determination method of salt spray test results includes rating judgment method, weighing judgment method, determination method of corrosive material and statistical analysis method of corrosion data.1) rating determination method: the corrosion area and the total area ratio of the percentage of a certain method is divided into several levels, with a certain level as a basis for qualified, suitable for Cemented Carbide Inserts flat panel evaluation.2) Weighing Judgment: The corrosion resistance of the sample is evaluated by calculating the weight (or weight gain) of the corrosion loss by changing the weight of the sample before and after the corrosion test. It is suitable for assessing the corrosion resistance of a metal.3) Determination of corrosive method: is a qualitative determination method, it is the salt spray corrosion test products after the corrosion phenomenon to determine the sample, the general product standards are mostly used in this method.4) Corrosion data statistical analysis method: mainly used for analysis, statistical corrosion, rather than specifically for a specific product quality judgment.
Source: Meeyou Carbide

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What Should We Do If Both Export Volume And Raw Material Prices Soar？

The raw materials prices have soared due to the following reasons: First, the prices of raw materials including copper, iron, aluminum, and plastics have continued to rise due to “supply shortages”; second, the prices of chemical raw materials have soared due to the collective closure of large global oil refineries. , Including furniture, home appliances, electronics, textiles, tires, paper, sheet metal and other industries are affected.

Main reason: epidemic situation and devaluation

The epidemic is Cemented Carbide Inserts raging in the global environment, affecting the development efficiency of global raw material resources, causing a decline in production capacity and an increase in raw material prices;

In addition, in the recent international relations environment, the depreciation of the U.S. dollar has led to a corresponding increase in the prices of raw materials that use U.S. dollars as the main transaction currency.

The price changes mean that the stable cooperation between some buyers and sellers will produce variables. At this time, strengthening the contact with existing potential customers may bring you unexpected opportunities;

Formulating a reasonable quotation plan and negotiation strategy, and if necessary, some concessions to customers will be a direction worthy of attention for foreign traders in the current tungsten carbide inserts market development.

The Tungsten Carbide Blog: http://itime.blog.jp/

Vibration-Free Turning Isn’t as Difficult as It Used to Be

Vibration in a turning operation can be maddening. It leads to results that can?be oh?so close, yet so far away. It’s difficult to diagnose the cause. And it can be even more difficult to fix—reducing speeds, feeds, introducing sharper cutting edges or reducing depth of Carbide milling inserts cut are all options, but each is a drag on productivity.

So, what to do? How does one maintain quality without sacrificing the all-important productivity levels in turning work? We believe we’ve got the answer.

We’ve taken our Smart Damper technology, which has proven itself in some of the most challenging vertical, horizontal and multi-axis boring applications on Earth, and brought it to the world of turning. Packed with proprietary damping technology, the rugged boring bar single?handedly helps limit one of turning’s most common and impactful challenges.

Here’s how it works.

It incorporates a passive damping mechanism that functions as a counter action by way of high resonance friction action. The patent-pending system’s damping capability minimizes the effects of high frequency oscillations, absorbing vibration effectively and allowing higher machining accuracy. It’s also designed with the capability of Carbide Stainless Steel Inserts supplying coolant through the body directly to the cutting edge.

The Smart Damper boring bar features three modular insert holders, optimized for right-hand I.D. turning with ISO standard inserts at a minimum diameter of ?1.58 inch. Metric bodies are available in ?32 & 40mm, with inch versions at ?1.250 & 1.500”. The general rule of thumb with this system is boring depths are possible at approximately 7xd.

For further details about the Smart Damper?dynamic integrated damping system for boring, click?here.

For further details about the Smart Damper?dynamic integrated damping system for milling, click?here.

The Tungsten Carbide Blog: http://good-luck.publog.jp/