MECHANICAL WORKSHOP

ACTIVITY 4
- J4102-

NAME LECTURER: EN. SHUHAIRI BIN MOHD

SAMSUDIN

PRESENTATION: GROUP 3
TOPIC: CARBIDE FUNDAMENTALS
TEAM OF GROUP- 3
CARBIDE FUNDAMENTALS

 1:RAJA MUHAMMAD FADZRIL BIN RAJA JOHAR SHAH
 2:MOHD AZIZI BIN BAHAROM
 3:MIR HARRIS BIN AHMAD
 4:MUHAMAD TAUFIQ BIN ZAKARIA
 5:MEOR ASNAWI BIN MIOR SADON

Describe how carbide insert are made.

 A common cutting tool material developed by the combination of carbon with usually
chromium, tungsten, or titanium that is used in metal cutting tools for its hardness
and wear resistance.

 For carbide cutting are made that a cutting bit made of hard carbide material that
has multiple cutting edges.


 Once a cutting edge is excessively worn, it can be indexed to another edge, or the
insert can be replaced.
State the two main
char acteristics of carbide.


 Cemented carbide, also called tungsten-carbide cobalt or hardmetal or widia,

is a hard material used in machining tough materials such as carbon steel or
stainless steel, as well as in situations where other tools would wear away, such
as high-quantity production runs.

 Most of the time, carbide will leave a better finish on the part, and allow faster
machining. Carbide tools can also withstand higher temperatures than standard
high speed steel tools.

Selection of carbide tool g r ade.
 Carbide Grade Applications
 


 (C-2 / K20) Uncoated grade used primarily in mild cutting

conditions. Used for milling steel, cast steel and other non-
ferrous alloys.
 


 (C-5 / P30) For roughing to semi-finishing of steel.

 


 (TiN-55) Multi Layer CVD coating (TiN/TiC/TiCN/TiN)

For milling and turning carbon and alloy steels, tool steels
Coatings for carbide insert.
 To increase the life of carbide tools, they are sometimes coated. Four such coatings
are TiN (titanium nitride), TiC (titanium carbide), Ti(C)N (titanium carbide-nitride),
and TiAlN (titanium aluminum nitride). (Newer coatings, known as DLC (Diamond
Like Coating) are beginning to surface, enabling the cutting power of diamond
without the unwanted chemical reaction between real diamond and iron.)
 Most coatings generally increase a tool's hardness and/or lubricity. A coating allows
the cutting edge of a tool to cleanly pass through the material without having the
material gall (stick) to it. The coating also helps to decrease the temperature
associated with the cutting process and increase the life of the tool.
 The coating is usually deposited via thermal CVD and, for certain applications, with
the mechanical PVD method. However if the deposition is performed at too high
temperature, an eta phase of a Co6W6C tertiary carbide forms at the interface
between the carbide and the cobalt phase, facilitating adhesion failure of the
coating.

Tool-nose radius
 The nose radius, Figure 6-9, will affect tool strength and surface finish.


 The larger the nose radius, the stronger the insert and the better the finish.

 However, if tooling and setup are not rigid, a large nose radius can cause
 chatter.


 The chart in Figure 6-10 indicates the smoothness of surface finish

 that should result from various combinations of nose radii and feed rates.
Insert shape
 Different insert shapes accomplish specific types of machining operations on
various workpiece shapes.


 See Figure 6-7. The strength of the insert also depends on the shape of the
insert.

 For example, the round insert has the greatest strength and the most cutting
edges, while the 35� diamond insert has the lowest strength. The triangular
insert is very versatile for milling operations.
Insert size
 Insert size is determined by the largest inscribed circle (IC) that will
 fit inside the insert or touch all edges of the insert, Figure 6-8.


 The most common insert is a ¾� square. As the size of the insert increases, the
depth of cut can increase as well. A rule to follow is to set the depth of cut to no
 more than 2/3 the cutting edge length.



Rake angles
 The rake angle has a primary influence on cutting forces and consequently the
cutting torque and surface finish of the thread.
 Test results made with different rake angles are shown in the above diagram,
illustrating how cutting torque decreases with a larger rake angle.
 There is, however, a limit. A large rake angle means lower strength of the cutting
edge.
Lead angle
 Lead angles on a milling cutter have an effect on cutting force direction, chip
thickness, and tool life. Lead angles can be 0 degree, 15 degree , 20 degree, and
45 degree . A 0 degree lead is used to produce a 90 degree shoulder. See Figure
6-5.


 For general milling applications where rigid conditions exist, 15 degree and 20
degree leads are used.

 A 45 degree lead angle allows higher feed rates to be used.


 As the lead angle increases from 0 degree to 45 degree , the amount of entry shock
minimizes.


Figure 6-5. An example of an insert with 0 degree lead

angle, is used to create a 90 degree shoulder.
Choo se inser t for various
applications
 A standardized letter and number system developed by ANSI,
 Figure 6-11, is used to identify and classify indexable carbide inserts. The
 identification reference is a combination of nine letters and numbers. The
 reference indicates the insert shape, clearance (relief angle), tolerance,
 insert type, size, thickness, point (nose) radius or chamfer, cutting edge
 condition, and (optional) manufacturer’s identifier.
Carbide Insert
Steel & Stainless (Toshiba)

Aluminum & Plastics (Vardex)

Tool Holders

Boring Bars
Describe how tool holder s ar e
identified.
 By confining the expensive hard cutting tip to the part doing the actual cutting, the
cost of tooling is reduced. The supporting tool holder can then be made from a
tougher steel, which besides being cheaper is also usually better suited to the task,
being less brittle than the cutting-edge materials.
 The tool holders may also be designed to introduce additional properties to the cutting
action, such as
 Angular approach - direction of tool travel.
 Spring loading - deflection of the tool bit away from the material when excessive load
is applied.
 Variable overhang - the tool bit may be extended or retracted as the job requires.
 Rigidity - the tool holder can be sized according to the work to be performed.
 Direct cutting fluid or coolant to the work area.
 Note that since stiffness (rather than strength) is usually the design driver of a tool
holder, the steel used doesn't need to be particularly hard or strong as there is
relatively little difference between the stiffnesses of most steel alloys.

Diagram

Diagram 1: In order to identify each of the many

varieties of carbide inserts, part numbers are
printed directly on the inserts. (Seco Tools AB)
THANKS FOR WACTHING.
THE END.
CARBIDE FUNDAMENTALS
1. Carbon compounded with a non-metal (such as boron, calcium,
or silicon) or metal (such as in cobalt, tantalum, titanium,
tungsten, or vanadium).
2. Metal carbides are characterized by their extreme hardness and
resistance to high temperatures, and are used as abrasives,
and in cutting, drilling, grinding, and polishing tools. See also
hard metal.
3.
Carbide insert
  
 Carbide Grade Applications
 
 (C-2 / K20) Uncoated grade used primarily in
mild cutting conditions. Used for milling
steel, cast steel and other non-ferrous
alloys.
 
 
 (C-5 / P30) For roughing to semi-finishing of
steel.
 
 (TiN-55) Multi Layer CVD coating
(TiN/TiC/TiCN/TiN)
For milling and turning carbon and alloy
steels, tool steels.
