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What is Tungsten carbide end mill and How to use carbide end mill correctly?

April 20,2023

tungsten carbide end mill is a cutting tool made of tungsten carbide, also known as tungsten-titanium alloy as raw material. Generally, it is mainly used in CNC machining centers and CNC engraving machines. It can also be installed on ordinary milling machines to process some hard and uncomplicated heat-treated materials. tungsten carbide end mill are versatile and can be used for high-speed machining. The Vickers hardness of Tungsten carbide end mill is 10K, second only to diamond. Therefore, the Tungsten carbide end mill is not easy to wear, and it is brittle, hard and not afraid of annealing.

Next, Zhuzhou OBT Carbide Tools Co.,Ltd will introduce the general classification of milling cutters.

1. Flat end mill:

used for rough milling, removal of a large amount of raw materials, precision milling of small horizontal planes or contours;

2. Ballnose end mills:

used for semi-finishing and finishing milling of curved surfaces; small ball end mills can be used for precision milling of small chamfers and irregular contour surfaces with steep angles/straight walls;

3. Special-shaped milling cutters:

including chamfering cutters, T-shaped milling cutters or drum-shaped milling cutters, tooth-shaped milling cutters, and inner R-shaped milling cutters;

4. Chamfering milling cutter:

The shape of the chamfering milling cutter is the same as that of the chamfering, and it is divided into milling cutters for milling fillet chamfers and bevel chamfers.

Then how to use carbide end mill correctly?

When milling with Tungsten carbide end mill, the workpiece can be fed in or relative to the direction of rotation of the tool, which affects the initial and finishing characteristics of the cutting process.

In the process of forward milling (also called co-direction milling) with Tungsten carbide end mill, the feed direction of the workpiece is the same as the rotation direction of the Tungsten carbide end mill in the cutting area. end tapers off.

In counter milling (also known as counter milling), the workpiece is fed in the direction opposite to the direction of rotation of the milling cutter in the cutting area. The chip thickness starts at zero and gradually increases during the cutting process.

During the up-cut milling process of the Tungsten carbide end mill, the blade of the milling cutter starts cutting from the zero chip thickness position, which generates a large cutting force and pushes the Tungsten carbide end mill away from the workpiece.

After the blade of the Tungsten carbide end mill is forced into the cut, it usually contacts the work-hardened surface caused by the cutting blade, which produces friction and polishing effects under the action of friction and high temperature. The cutting force also makes it easier to lift the workpiece off the table.

When the Tungsten carbide end mill is down milling, the blade of the milling cutter starts cutting from the position where the chip thickness is large. This avoids polishing effects by reducing heat and lessening the tendency to work harden.

Using a large chip thickness is very beneficial and makes it easier for the cutting forces to push the workpiece into the Tungsten carbide end mill, causing the blade of the cutter to perform the cutting action.

During milling with tungsten carbide cutters, chips can sometimes stick or fuse to the cutting edge and build up around the start of the next cut.

Chips are more likely to become trapped or wedged between the insert and workpiece during up milling, causing the insert to break. Instead, the same chips are split in two during forward milling so that the cutting edge is not damaged.

Regardless of the requirements of the machine tool, fixture and workpiece, forward milling is the method of choice. Since the cutting force keeps the workpiece down while pushing the insert forward, forward milling places certain special demands on the machining process.

This requires the machine tool to eliminate backlash to meet table feed requirements. If the tool is pushed into the workpiece, the feed rate will increase irregularly, causing excessive chip thickness and insert failure.

Up milling should be chosen in such applications. In addition, if there is a significant change in the machining allowance, up milling is more advantageous.

To properly clamp a workpiece, the proper fixture is required, and the operation requires the correct tool size.

However, the direction of the cutting force is more important for the vibration tendency.


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