Are Aluminum Milling Inserts Suitable for High Speed Machining Applications

Aluminum milling inserts are a popular choice for metalworking applications, particularly those requiring high-speed machining. As the technology of aluminum milling inserts improves, they have become increasingly suitable for high-speed applications. In this article, we will explore the advantages of using aluminum milling inserts in high-speed machining applications.

One of the biggest advantages of using aluminum milling inserts is their strength. Aluminum milling inserts are much stronger and more durable than other materials, allowing them to stand up to high speeds and heavy loads. Additionally, aluminum milling inserts are corrosion-resistant and have high heat resistance, making them ideal for high-speed machining applications.

Another advantage of aluminum milling inserts is their weight, or more specifically, their low weight. Aluminum milling inserts are much lighter than other materials, allowing for increased speed and precision in high-speed machining applications. As a result, aluminum milling inserts are able to cut at higher speeds and reduce RCMX Insert the amount of time needed to complete a job.

Finally, aluminum milling inserts are also beneficial in terms of cost. Aluminum milling inserts are generally more affordable than other materials, making them a cost-effective choice for high-speed machining applications. Additionally, aluminum milling inserts require less maintenance and can last longer than other materials, resulting in even greater cost savings.

In conclusion, aluminum milling inserts are a great choice for high-speed machining applications. They are strong, lightweight, and corrosion-resistant, allowing them to withstand high speeds and heavy loads. Additionally, aluminum milling inserts are cost-effective and require less maintenance than other materials. For these reasons, aluminum milling inserts are an ideal choice for high-speed machining SDMT Insert applications.

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The Use Sheet Metal Prototyping in Rapid Prototyping

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Posted on: May 6th, 2019, | By Candy, WayKen Marketing TNGG Insert Manager

Rapid prototyping is becoming more widespread as it proves its efficiency on a global scale. This term has appeared recently and was mostly associated with 3D printing but once the designers and product developers got the hang of it, the demand for rapid technologies has grown drastically. That’s why a lot of other plastic and metal prototype fabrication techniques are being developed to be called rapid. One of these is the sheet metal prototyping technique. Let’s see how cold sheet metal forming can be developed into a rapid prototype manufacturing method.

What Is Sheet Metal Fabrication Really?

Sheet metal forming is an important tool in manufacturing thin-walled structures from metals with good plasticity. The main advantage of the sheet metal fabrication process compared to other “pressure” processing operations is the fact that you don’t need to heat up the blank the way it’s done in stamping. Thin metal sheets can be bent while being cold. This results in a fast economic and sustainable manufacturing process. A lot of modern structures are made of sheet metals. Take the car, for example. Its body is completely made out of sheet metals. This makes the weight of the cars considerably smaller.

From Sheet Metal Forming to Rapid Prototyping

In order to understand what modifications are required to transform the conventional sheet metal manufacturing process into a rapid prototyping sheet metal technique, it is necessary to analyze where the most time-сonsuming actions occur. The main components of sheet metal forming include the following. A hydraulic(or powered by another drive) press to apply pressure. A die that is fixed on the plate of the press and has the aviary corresponding to the desired form of the final part. A punch, it is the part that presses on the sheet of metal and indents it into the die. The punch usually has a convex surface that Mimi is the concave surface of the die. There are a thousand other specific tools associated with sheet metal manufacturing but those are used to support the process rather than carry it out. We are going to focus on the most crucial elements of the system.

Where Sheet Metal Prototyping Can Be Improved

So, how can we improve the process to transform it into a quick turn sheet metal prototyping technique? For starters, the weakest link must be determined. In sheet metal forming, manufacturing custom dies and punches time determines the overall turnaround time of the sheet metal prototype. The dies and punches are usually made from heat-treated instrumental steel that is very hard to process. The most efficient way to shorten the lead-time of prototype sheet metal parts is to decrease the production of dies and punches. That can be realized in a number of ways.

Product lifecycle management. Manufacturing tooling is a product as well and PLM is an information product support system that drastically shortens the time for R&D stages, product design verification, resource management and planning, and NC program design. PLM integrates all the separate stages of product life and coordinates the manufacturing of the tooling.

Using simpler materials. Rapid prototype sheet metal manufacturing does not require the tooling to be very durable.? The majority of product developers need only a few sample sheet metal prototypes for tests so the die material can be much softer. For example, some aluminum alloys can be used. The dies made of such alloys are viable for a limited batch but the size of that batch may be just enough for the durability of the die. On the other hand, a softer material means a significantly shorter lead-time of the die.

Using modern CNC and CAM systems. A lot of dies have complex cavities or a lot of features. Manual machining will take too much time or will be downright impossible. That is why CAM systems are employed. They enable the manufacturers to create NC programs for any kind of die cavity.

Using interchangeable dies. Dies typically consist of the base elements used to fix them to the press and the cavity that is used to form the part. In order to save the amount of machining, it is possible to create the cavity separately. That way, the die will consist of two parts and its precision will be smaller but the prototypes typically do not require the perfect precision.

Avoiding automation. Modern mass production sheet metal fabrication processes are highly automated and it is beneficial in the long run. However, automation takes time to set up and verify and it only meddles with the prototyping. That is why it is actually good to avoid extensive automation in such complex areas as part loading, part unloading, sorting the blanks, transporting parts from one machine tool to the other and so on.

Metal Prototyping Services As A Shortcut To Rapid Sheet Metal Prototyping

Sheet metal prototype fabrication is by no means an easy task. If you are just starting out, it may be hard to master conventional forming to optimize the cost of sheet metal. In order to actually move on to the more advanced sheet metal prototyping, you will have to spend a lot of effort and money. But there is a shortcut.

If you are not sure you actually want to get into the quick turn sheet metal parts industry, for example, you are a developer or a designer and you just want to create your product and move it into the market faster without diving deep into all the steel, titanium or aluminum metal fabrication processes, metal prototyping services can be a good solution for you.

Sheet forming service companies have the advantage of purchasing cheap metal sheets at the stock price because they always Tungsten Carbide Inserts need a lot and the sheet manufacturers give them a discount. They have the latest equipment and the most experience since they earn money from manufacturing sheet metal parts. You will only need to provide a 3D model or the design drawing and they can give you advice on how best to fix it for manufacturing and will create a prototype batch for you in no time.

Rapid Sheet Metal Prototyping at Wayken

At WayKen,? we provide high-quality rapid prototyping services including?precision CNC prototyping, CNC milling, sheet metal stamping, SLA & SLS, Vacuum casting, surface finishing,?rapid tooling, etc for automotive parts, sheet metal parts, electrical appliances parts, home appliances parts, medical device parts, toy products, etc

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4 Main Factors to Determine how to Choose Cutting Lubricant You Need

After a long period of development in 1860, cutting fluid began to be widely used in vehicle, planer, grinding, gear processing and thread processing. With the development of cutting fluid, vegetable oil, edible oil, water and so on are gradually formed. I am often asked to recommend cutting fluids for metal processing equipment. In fact, choosing the right cutting fluid is very simple. In order to select the best oil, you need to collect some basic information about the selection criteria. For simplicity, you need to know the workpiece materials, basic machine types, tool details, and factory processes used.

Contents hide 1What kinds of cutting fluids are common? 2Workpiece materials 3Basic Machine Types 4Tool details 4.1Cemented carbide tools: 4.2Ceramic cutting tools: 4.3Diamond cutting tools: 4.4High Speed Steel Cutting Tools 5Factory TechnologyWhat kinds of cutting fluids are common?

In order to meet different processing requirements, there are many kinds of cutting fluids, which can be divided into water-based cutting fluids and oil-based cutting fluids according to chemical composition and state.

Generally, the cutting fluid diluted by water is called a water-based cutting fluid, and the cutting fluid used without water dilution is called oil-based cutting fluid.

• Water-based cutting fluids are mainly cooled and have poor lubricity. The commonly used water-based cutting fluids are a rust-proof emulsifier, rust-proof lubricant emulsifier, extreme pressure emulsifier, and microemulsion.

• Oil-based cutting fluids are mainly lubricating but have poor cooling and cleaning effects. The commonly used oil-based cutting fluids are pure mineral oil, fat oil + mineral oil, inactive extreme pressure cutting fluids, active extreme pressure CCGT Insert cutting fluids, etc.

Next, I have arranged a table to introduce the types and characteristics of cutting fluids in detail.

category	type	composition	characteristics
water soluble	Antirust Emulsion	It is composed of mineral oil, emulsifier, rust inhibitor, etc. The content of mineral oil is about 50%~80% in water to form an oil-in-water emulsion.	Compared with oil-based cutting liquid, the advantage of emulsifier is a good cooling effect. Generally, the water solution diluted by 5%~10% has a lower cost and is safe to use. The biggest disadvantage of emulsifier is its poor stability, susceptibility to bacteria and molds, and short use period.
	Rust-proof lubricant emulsion	Contains Carbide Turning Inserts animal and vegetable fats or long-chain fatty acids (such as oleic acid). A small amount of sodium carbonate, sand or sodium benzoate can be added to the emulsion to prolong the service life.	It has good lubricity, but the disadvantage is that these animal and vegetable fats or long-chain unsaturated fatty acids are easy to be decomposed by microorganisms and fungi, and the use cycle is very short.
	Extreme Pressure Emulsion	It contains oil-soluble sulfur, phosphorus and chlorine extreme pressure additives.	It has strong extreme pressure and slippery property. It can be used for Equal-Weight cutting such as achievement, broaching and banding. It can also be used for processing difficult-to-cut materials such as stainless steel and heat-resistant alloy steel.
oilbased	Fat-proof oil (or oily additive) +mineral oil	Commonly used fat oils are rapeseed oil, soybean oil, lard and so on.	Oil-proof grease has strong adsorptive property to metal surface and good lubrication performance. Its disadvantage is that it is easy to oxidize and deteriorate, and forms a mucous film (yellow gun) which is difficult to clean on the surface of machine tool. It is generally used in precision cutting such as finish turning soft rod, gear hobbing, gear making and so on.
	Active Extreme Pressure Cutting Fluid	It is made of mineral oil and sulfur extreme pressure additive with strong reactivity.	It has good sintering resistance and very long lubricity, can improve the service life of cutting tools under high temperature and high bed conditions, and has strong control ability for cutting tool debris. It is mostly used for cutting materials which are easy to gnaw and difficult to machine.
	Inactive extreme pressure cutting fluid	It is composed of mineral oil and inactive extreme pressure additives.	Extreme pressure lubrication is good for non-ferrous metal corrosion. Easy to use, widely used in a variety of processing environments

So, back to the initial subject, how to choose cutting fluid for different tool materials

Understanding the types and characteristics of cutting fluids, which four factors need attention?

Workpiece materials

Some metals are more difficult to process than others. Stainless steel, foreign alloys, and very hard metals require high performance cutting fluids. Other metals, such as brass and aluminum, are easily processed with general-purpose oils.

If hard and low machinability metals are involved, high addition cutting fluids with excellent extreme pressure (EP) and welding resistance are required. In most cases, these oils contain active sulfur and chlorine to protect tools and ensure good parts finish.

For brass, aluminum, many carbon and low alloy steels, cutting fluids containing lubricant additives, friction modifiers, and low extreme pressure/welding resistance are sufficient. These oils are usually formulated with sulfurized fats (inactive) and/or chlorinated paraffins. Active cutting fluids (containing active sulfur) should not be used for brass and aluminum because they can contaminate or stain finished parts. Oils for brass and aluminum are often referred to as “non-dyeing” oils.

Basic Machine Types

The type of machine will also determine the characteristics of some cutting fluids. For example, there is serious cross-contamination between lubricating oil and cutting fluid of screw machine. Therefore, these machines often use dual-purpose or triple-purpose oils that can be used in lubrication boxes, hydraulic systems and cutting fluid pools.

Lapping machines, gun drills, and deep hole drills require lighter viscosity oils to achieve high-speed cooling, good chip and chip washing, and no foam production through tool delivery and high-pressure applications. Manufacturers of CNC raw equipment may limit cutting fluids because they may not be compatible with machine parts such as seals. Centerless grinders may require a harder fluid than surface grinders.

Be ready to discuss plant equipment when suppliers are asked to provide suggestions for metalworking fluids.

Tool details

Certain cutting fluid additives cannot be used effectively with specific coatings, and incorrect abrasive oils can lead to wheel loads and other problems. If you spend the extra money on carbide tools, cobalt coatings or cubic boron nitride (CBN) grinding wheels, it makes sense to choose a cutting fluid that maximizes performance and economic returns.

Cemented carbide tools:

Cemented carbide is composed of tungsten carbide (WC), titanium carbide (TiC), tantalum carbide (TaC) and 5%-10% cobalt. Its hardness is much higher than that of high-speed steel. Its maximum allowable working temperature can reach 1,000 C. It has excellent wear resistance and can reduce the bonding phenomenon between chips when processing steel materials.

Because of the good red hardness of cemented carbide cutting tools, dry cutting is usually used in the processing of general materials without cutting fluid.

1	In dry cutting, the high-temperature rise of the workpiece makes the workpiece easy to produce thermal deformation, which affects the workpiece processing accuracy. Therefore, when choosing cutting fluid, the sensitivity of cemented carbide to sudden heat should be considered, so that the tool can be uniformly heated as far as possible, otherwise, it will lead to edge collapse.
2	For high-speed cutting, the cutting area should be sprayed with large flow cutting fluid to avoid tool thermal unevenness and edge collapse and to reduce soot pollution caused by evaporation due to excessive temperature.

Generally, the thermal conductivity of oil-based cutting fluids is poor, and the risk of tool sudden cooling is smaller than that of water-based cutting fluids. Therefore, oil-based cutting fluids containing anti-wear additives are generally suitable. When cutting with cutting fluid, attention should be paid to the uniform cooling of the tool. It is better to pre-cool the tool before starting the cutting.

Ceramic cutting tools:

This material is sintered by alumina, metal, and carbide at high temperature. Its high temperature wears resistance is better than that of cemented carbide. Therefore, dry cutting is generally used.

Considering uniform cooling and avoiding excessive temperature, water-based cutting fluid is often used, but it is better to pour continuously and sufficiently without interruption.

Diamond cutting tools:

Diamond cutting tools have very high hardness, generally using dry cutting. In order to avoid excessive temperature, water-based cutting fluids are used in many cases, just like ceramics.

High Speed Steel Cutting Tools

This material is high-grade alloy steel based on chromium, nickel, tungsten, molybdenum, and vanadium (some also contain aluminum). Its heat resistance is obviously higher than that of tool steel, and the allowable maximum temperature can reach 600 C. It has high toughness and is suitable for complex geometry workpiece and continuous cutting, and high-speed steel has good machinability and price acceptability.

Because of the poor redness and hardness of high-speed steel cutting tools, cutting fluid is needed in use.

1	Oil-based cutting fluids or emulsifiers are recommended for low and medium speed cutting.
2	In high-speed cutting, water-based cutting fluid is suitable because of its high calorific value.
3	Extreme pressure emulsifier or cutting fluid are used in finishing to reduce friction, improve surface quality and accuracy, and prolong tool life.

If oil-based cutting fluid is used, there will be more oil mist, which will easily cause workpiece burns, reduce the quality of processing and increase tool wear. In addition, extreme pressure water solution or extreme pressure emulsifier is recommended for rough processing.

Factory Technology

Cutting fluids must meet your production requirements without causing problems in downstream activities. Fluids most suitable for mechanical processing applications may cause serious problems in cleaning, painting, packaging or treatment. A review of downstream processes, including storage and transportation, will determine the key requirements that metalworking fluids must meet. Identifying these requirements early in the selection process will avoid wasting time and money in testing and installing the wrong fluids.

Anyway, cutting fluids can affect your equipment, personnel, environment, and business reputation. If you take the time to choose carefully, buy quality products from reputable suppliers, and seek competent technical advice, you will get considerable returns. Correct selection will improve product quality, reduce manufacturing costs and avoid costly downstream problems.

Now you must know how to select premium cutting lubricant per your requirement. subscribe to us now to get more alike blogs that are helpful to your project.

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CNC： Cycle time reduction by controlling what the spindle does at tool change

APKT Insert

CNC: Cycle time reduction by controlling what the spindle does at tool change

On a CNC lathe, what you do with the spindle during tool change can make a difference to the cycle time, and help in cycle time reduction. The spindle takes some time to accelerate to the programmed speed. The larger the lathe, the more time it takes, because of the higher size and inertia of the spindle. A typical machine would take 1 sec. for every 1000 RPM. E.g., 3 secs. to reach 3000 RPM.You can do one of 3 things:1. Stop the spindle before moving to the tool change position. Restart it after the tool change.

Result: When the tool approaches the next operation, the machine will wait at the destination position for the spindle to accelerate to its programmed speed. To save time you can program the spindle start during the approach to the operation from the tool change position, but even then the rapid motion will take less time than the spindle acceleration, and the machine will wait. E.g., if you are turning a 50 dia. part at 300 m/min, the spindle accelerates to 1900 RPM each time, taking approx. 2 seconds – for 5 tool changes that’s 10 seconds.

During spindle acceleration the power consumption is momentarily very high (you can see the power meter going beyond 120 %). This increases the power bill, reduces the motor and spindle life.

2. Keep the spindle running in CSS (Constant surface speed) mode, with the same surface speedResult: The spindle slows down to a very low speed as the tool moves to the tool change position (because the diameter at the tool change position is very large), then speeds up again to a high RPM when the tool approaches the operation area. Almost the same effect as option 1, but slightly better – the spindle starts from some speed instead of from zero. Taking the same example, if the tool change position is at 200 dia., the spindle decelerates to 475 RPM each time and then accelerates to 1900 RPM, taking approx. 1.5 secs.

3. Keep the spindle running with CSS OFF

before tool change, switch back to CSS ON after tool change. Change only the mode, not the surface speed. Result: The spindle is running at the same RPM as when cutting was going on, does not decelerate or accelerate during the motion to and from the tool change position. There is no time lost.

Action point

Option 3 is the best option: Switch to Constant spindle speed mode before tool change, back to CSS mode after tool change.

Cadem’s CAPSturn CNC lathe programming software reduces cycle time drastically by taking care of this automatically. It is a CNC offline programming software and conversational CAM software.

Want to reduce waste of machine capacity in your shop floor, improve profits via Industry 4.0 ? Check out our LEANworx CNC machine monitoring system. You start seeing big results in just a couple of weeks.

Want to just learn what Industry 4.0 is ?We have a great blog on what is Industry 4.0.

Etc.

Fauja Singh – ‘Turbaned Tornado’

Here’s someone I find very inspiring. Fauja Singh, born in 1911, migrated from Jalandhar to England about 25 years ago. His first marathon (a 42 km. road run) was in 2000 in London. This was at the age of 89, when he started running to ovecome the death of his wife and son. He stopped running in 2013, at the age of 101, after completing a Hong Kong 10 km. run in 1 hour 32 minutes.

He’s run the marathon 8 times so far. His latest was the Toronto marathon last year, at the age of 100. He took 8 hrs. 25 minutes, and came in last. Kenneth Mungara of Kenya came in first, at just over 2 hrs. – but then he’s 62 years younger than Fauja Singh.

At the age of 100, Fauja Singh broke eight world records for the 100+age group in one day in Toronto, Canada : 100 m., 200m., 400 m., 800 m., 1500 m., 3000 m., 5000 m., 1 mile.

He ran the 100 metres in 23.14 seconds (the average person in his twenties would do it in 12).

In each one he improved upon the previous record in that age division (some events had no previous record holder, as nobody over age 100 had ever attempted to run the distance).

A video of the Turbaned Tornado in the london marathon : http://www.youtube.com/watch?v=gCY0Xx92YvQ

He’s a vegetarian, and the oldest person to be featured in a PETA (People for Ethical Treatment of Animals) campaign. Check out the slogan ‘Sikhs and the city’ on his T-shirt in the pic above. A take off on ‘Sex and the City’, a TV series later made into a movie.

http://en.wikipedia.org/wiki/Sex_and_the_City

About the marathon, Fauja Singh: “The Carbide Turning Inserts first 20 miles are not difficult. As for last six miles, I run while talking to God.”

As for me, I say : “The first 3 miles I run with some difficulty. As for last 23 miles, I leave them for God to run”. For some strange reason, I can cycle quite long distances at a stretch, but can’t run even short distances. Must be a different bunch of muscles used in each activity.

Related posts:

Constant surface speed and Limiting spindle speed

Quick change tool holder systems on CNC lathes

Constant cutting speed – benefits in CNC lathes

G76 Fanuc threading cycle, and depth of cut in CNC threading

Cutting speed and RPM (or spindle speed) – the difference

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Tungsten carbide blade manufacturing process

The main components of cemented carbide blades are tungsten carbide and cobalt in different proportions. The original form of the raw materials is powder; a container Cemented Carbide Inserts weighing about 560kg contains the prepared raw materials, which will be used to produce different powders; in the workshop Here, the dry raw materials are mixed with a solvent made of ethanol and water to form a gray paste with a consistency similar to yogurt; after the paste is dried, the sample is sent to the laboratory for quality testing; these powders are composed of many It is composed of particles with a diameter of 20-200μm, which are very small (the diameter of a hair is 50-60μm).

The stamped cemented carbide blades need to be heated to harden. This work is completed by a sintering furnace, which can process thousands of blades at a time; the pressed blade powder is heated to about 1,500°C in a 13-hour process. It melts and becomes cemented carbide, which is a very hard material; the shrinkage ratio in the Carbide Milling Inserts sintering process is about 50%, so the blade size after sintering is only half of the previous one.

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