How Does Tungsten Filament or Tungsten Cathode Work？
Speaking of buying cemented carbide blades, most people may say that it is not just buying things? Who can do it? In fact, it is easy to buy things, but it is not so easy to buy good things. Let's take alloy blades as an example. We are very particular about buying them. Not all carbide blades can be purchased.
When buying hard alloy blades, you must choose good quality products. This is a commonplace talk. The question is how to know if the quality of the product is good. Here, if it is a large user enterprise, the use SNMG Insert of blades is relatively large, so at this time, you can use professional inspection tools for inspection.
If it is an ordinary user or a consumer, then it is only necessary to observe the product itself to draw a conclusion. In fact, here, we don't necessarily have to choose the best quality blades. Different blades have different uses. Some users do not have high requirements for the blades. So at this time, as long as the quality of the blade can meet your needs, you don't have to choose top quality blades.
Secondly, there is another issue that must be considered when buying hard alloy blades, that is the price of the product. In economics, there is such a law that value determines price. Conversely, the higher the price, the higher the value contained in the product. However, we also said that it is not necessary to choose the best quality product, as long as it can meet your own needs. Therefore, the price is also the same. It is not necessary to choose a particularly expensive blade, as long as it is moderate.
In addition, you must pay close attention to the model of the product when purchasing hard alloy blades. We know that different blade models are tungsten carbide inserts suitable for different price plates, some are suitable for processing cast iron, and sometimes for processing steel. In addition, rough machining and finishing have different requirements for the insert. Therefore, from this perspective, you must choose according to your own needs when choosing.
Fault analysis of cemented carbide boring cutter
Milling a curved surface falls under the umbrella of profile/ contour CNC milling. It involves machining irregularly shaped profiles or continuous curves with various degrees (either slanted, concave, or convex). This is a crucial process in getting most of the uniquely shaped bespoke parts done, which requires the CNC machining services providers to have advanced knowledge of the fundamental machining principles and programs.
Fundamentals to Profile CNC Milling
1.? Profile CNC Milling Processes
Before arriving at the final machined part, it will be first subdivided into different categories: roughing/ semi-roughing, semi-finishing, finishing, and super-finishing. The larger the component, the more operation types will be involved. It is important to sub-categorize the operations in machining a work part so that you would be able to maximize the full potential of the tooling and parameters you will be using.
Roughing- This operation is always the first stage of machining and usually begins with cutting the raw material block to shape the part approximately near the desired shape or profile, leaving enough metal stock for further operations.
Semi-finishing- This process involves machining the part as per dimension requirements or removing the remaining stock on the part. Semi-finished parts may also be subjected to further processing to achieve a specific requirement for surface finish.
Finishing- This process comes after the semi-finishing operation. Finishing is done to improve the part’s Carbide Drilling Inserts surface finish by removing obvious burrs and other surface flaws. In this operation, it is essential to use high-performing tools because this will significantly affect the work part’s final appearance.
Super-finishing- the operation goes further until super-finishing if the parts require a mirror finish or a super smooth profile. For this to be achieved, high-speed machining techniques and high-precision tools are used.
2.? Get to Know the Tools Used in CNC Milling Curved Surface
To come up with smooth-curved surfaces on a part being fabricated, different variations of rounded end mills are used. These include rounded inserts, ball nose indexable end mills, and ball nose solid carbide. Round-profiled toolings are preferred for contouring applications because it Carbide Aluminum Inserts does not leave evident marks of the tool path.
Insert-type end mills with rounded inserts- These tools often come in large tooling diameters. Rounded insert type end mills are well suited for roughing operations due to their high stability and impressive productivity.
Solid ball nose end mill- These end mills can leave a very nice surface finish on a machined part. They may have low stability due to their structure. That is why they are more commonly used for finishing than for roughing operations.
Indexable head ball nose end mills- Indexable head end mills are similar to solid carbide end mills but have exchangeable heads. These special toolings have a detachable end which may be replaced when needed.
General Tips for CNC Milling Curved Surfaces
1.? Necessary Preparations
Before deciding to fabricate your custom parts through profile milling, it is also essential that you become aware of the various factors that may affect the whole CNC milling process. In addition to this, there are specific things you need to identify so that you can properly choose the suited machining technique. Below are some of the things you need to be prepared about:
- Be mindful of the cavity depths of your part designs- This plays a significant role in helping you choose the right cutting tools to use and how long will be the gauge length you will be needing.
- Know how much material will be subtracted from the raw block- This will help you plan for the operations required in fabricating your work part, whether you will need additional procedures after semi-finishing and semi-roughing.
- Consider how you will clamp the workpiece in place- This will help you prepare for the necessary fixtures you will be needing.
2.? The Old And Classic: Get Your Feeds And Speeds Right
Feeds and speeds determine the rate of material subtraction on the parts, which is why they have a significant impact in achieving an excellent surface finish. For this, calculations are needed to be followed. Feed rates to be used may also be dependent on the depth of cut, the tooling used, the material to be cut, the profile of the part being machined, and the accuracy required.
Disclaimer: We will not mention actual values for the speeds and feeds in this article because these values may vary depending on multiple factors. It is still recommended to refer to trusted references for the actual speed and feeds. Nevertheless, here are the basic rule of thumbs:
The depth of cut and feed rate varies depending on the hardness of the materials being machined. Take note that for harder materials, the feeds and depth of cut are much lower than that of softer materials like aluminum. Furthermore, the harder the material to be cut, the faster the cutting speed should be.
Feed rates and depth of cut for roughing operations are much more aggressive than finishing operations. It is the combination of using high-speed techniques and the right tools that make an excellent surface finish.
3.? Tooling Utilization
There are many variations of tools available in the market nowadays. For roughing operations, tooling rigidity should be prioritized to withstand the aggressive cut depth and feed demands of roughing. On the other hand, for finishing operations, the end mills should be very sharp not to leave any evident trace of the tool path. Another difference is the tool diameter used. Typically, roughing tools have larger diameters than that of the finishing tools.
4.? Minimize Vibration In Your CNC Milling Processes
Vibration is one of the major causes of undesirable surface finish, chatter, and cutting tool damage. During a milling operation, the vibrations may be coming from multiple sources, including clamping stability, tool rigidity, material hardness, and inaccuracies in the machine spindle. Below are some of our tips to minimize this machining obstacle:
- Use tools with good runout accuracy
- Avoid having too long overhang in your end mills during roughing operations. Instead, use extension bars or extension tool holders
- Secure your work holding fixtures by ensuring that proper grip and balance are maintained during the cutting operations.
- Avoid aggressive cuts when dealing with hard metals.
Conclusion
CNC milling curved surfaces are usually subdivided into different operations (roughing, semi-finishing, finishing, and superfinishing) so that the desired profile is achieved gradually. The toolings used for this type of milling typically have rounded profiles or what is commonly called ball nose end-mills. In summary, CNC milling a curved surface involves doing the necessary preparations, getting the feeds and speeds right, being mindful of the tools you will be using, and minimizing vibrations.
The basic essentials of choosing cemented carbide blades
Cemented carbide tools have a wide range of applications in the industrial market, and their excellent properties are favored by customers. So, do you know what factors affect the life of cemented carbide tools? Please allow Betalent to answer this.
The service life of cemented carbide tools is generally affected by three aspects. They are the preparation of the tool substrate, preparation of the cutting edge, and the choice of coating.
1. The tool substrate of cemented carbide tools
CNMG InsertThe particle size of WC can determine the substrate properties of cemented carbide tools. The larger the particle size, the stronger the toughness of the tool. The smaller the particle size, the better the wear resistance of the tool. The cobalt content of the tool can also be controlled at 6%~12% to obtain good toughness.
2. Preparation of the cutting edge of cemented carbide tools
The preparation of the cutting edge of cemented carbide tools is also called edge passivation, which is an important factor affecting the success or failure of machining.
Generally used for continuous turning and milling of most steel and cast iron inserts, a greater degree of cutting edge passivation is required.
On the contrary, the blades used for processing stainless steel and high-temperature alloys Lathe Inserts are prone to form built-up edge, so the cutting edge is required to be sharp and can only be slightly passivated.
3. The choice of coating for cemented carbide tools
The coating can improve the cutting toughness of cemented carbide tools to a certain extent.
Coating technology includes: titanium nitride coating, nitrogen aluminum titanium coating, titanium carbonitride coating, chromium nitride coating, diamond coating and so on.
Betalent can have high-quality tool substrate, coating and mature cutting edge preparation technology, and customize sophisticated carbide tools for customers.
Using AI to Predict CNC Machine Spindle Issues Before They Are Issues
In addition to an innovative wire changer, the Robofil 2030SI-TW offers a Surface Integrity feature that minimizes the recast layer. This feature is said to be especially suitable for machining carbide.
GFAGIECHilles' dual-wire machine can switch automatically between EDM wires of two different diameters. This close-up shows the machine's twin wire feeding mechanism, its "automatic tool changer," so to speak.
This diagram of a multi-cavity die with various minimum radii and surface finish requirements Cemented Carbide Inserts shows how cutting with two wires reduces overall production time.
PreviousNextThe development of automatic "tool" changing for wire EDM (electrical discharge machining) promises to revise the process strategies applied to many wirecut workpieces. This trend is already apparent following the introduction of dual-wire machines by Agie Charmilles Technologies (Lincolnshire, Illinois). These models, the Robofil 2030SI-TW and the Robofil 4030SI-TW (the TW designation stands for twin wire) are reportedly the first wire machines with the capability to change from one size wire to another automatically. "Slugless" machining, for example, becomes a more attractive option.
An EDM wire of a larger diameter (0.010 inch would be typical) is used to remove all of the material in an opening as a kind Cutting Tool Inserts of roughing operation, where the wire follows a path similar to a pocketing routine in milling. This roughing procedure does not produce the slug usually created when the wire follows only the outline of the portion to be removed. After roughing out the opening, a finishing operation follows with a wire of a smaller diameter (0.004 inch perhaps). The smaller wire is used to produce sharper corners, reach a tighter dimensional accuracy and achieve a finer surface finish with additional skim cuts.
According to GFAGIECHilles, implementing this strategy on its dual-wire machines typically saves from 30 to 50 percent of the time normally taken, depending on the application.
Without automatic wire changing, openings could be cut with the large-diameter wire, then recut with the small wire after a manual wire change. For workpieces with numerous openings such as a lead frame die or multi-cavity mold component, manual wire change time adds up to a significant part of total process time. Another possibility is to cut all of the openings with the smaller wire. This approach minimizes loss of precision during manual wire changing and re-alignment. However, cutting speed is proportional to wire diameter, so the cutting time for the fine wire is considerably longer and the operator must be prepared for timely slug removal. Either of these scenarios rules out prolonged unattended operation, the mode in which EDM operates most economically. Both scenarios are also likely to keep the workpiece in water longer than the dual wire approach, increasing the risk of corrosion.
The dual-wire machines are equipped with two separate wire circuits located side by side on the front panel to bring the two wires down to the upper head guiding zone. Changeover from one wire to the other takes about 45 seconds and occurs without operator intervention. Each machine's on-board CT-Expert system automatically generates the machining parameters and tool paths for both wires, selecting the correct wire and wire settings for each programmed wire switch.
The Robofil 2030SI-TW handles workpieces as large as 1,130 by 510 by 260 mm (44.4 by 20.0 by 10.2 inches) and weighing as much as 500 kg (1,100 pounds). The Robofil 4030SI-TW handles workpieces as large as 1,150 by 725 by 360 mm (49.2 by 28.7 by 14.2 inches and weighing as much as 800 kg (1,765 pounds). Both machines can accept wire spools weighing as much as 55 pounds.
Adaptive control in CNC – what is it, and what are its benefits ？
Posted on June.21th, 2023, | By Kenzi, WayKen Project Manager
Jewelry manufacturing is one of the oldest trades of the world, however, it is early to say that everything that could be useful for manufacturing jewels has already been invented. Progress moves on and CNC Rapid Prototyping of Jewelry can be improved with metal rapid prototyping services as well as laser and water jet cutting. You will be able to know how by reading this article.
The Conventional Process of Manufacturing Jewelry
Jewelry has been traditionally manufactured by casting. That is so because precious metals have good casting properties and the mold can be made with very low surface finishes. The casting process is fast and has good repeatability. However, it requires a master model. The overall quality of the mold and the cast part is highly dependent upon the quality of the master model? So, how were they manufactured originally?
Master models are conventionally made from wax. That usually meant them being carved from a piece of wax by the jeweler. The process was time-consuming and required a lot of skill from the manufacturer.
Once the master model is complete, it is encased in a special substance similar to concrete. You heat up the substance once it has solidified and the wax is evaporated from the concrete. Then you pour molten metal and break the concrete mold to get the jewel out. So, you have to make the master model for each piece from scratch.?Modern industry and the consumer simply doesn’t provide enough time to manufacture jewels commercially this way. If you manufacture each master-model manually, you won’t produce enough products at the required rate and your competitors will overcome you. This is where CNC rapid prototyping comes in handy.
How to Speed up Your Jewelry Business with CNC Machining Services
CNC Machining Services
There is a number of good options CNC prototyping can offer to increase your jewelry business competitiveness. At WayKen, not only CNC metal machining is useful but wax machining and laser and waterjet cutting can be a successful addition in the jewelry business as well.
CNC Jewelry Master-Models
The first thing that comes to mind is implementing CNC machining to manufacture wax master models. And it really is an efficient way implemented in a lot of modern plants. However, you can’t use any simple CNC machining equipment and cutting parameters as the wax is easily bent and melts under high temperatures. In addition, since it’s very soft, you’ll need extremely high spindle speeds ( up to 70,000 rpm). Overall, you will be able to manufacture wax master models at a terrific rate. Additionally, laser and water-jet cutting techniques are highly useful for this type of work as well. They generate little heat and can be further cooled down with special coolants.
Manufacturing Metal Molds
Another efficient way to manufacture cast rings or bracelets is to make reusable molds through metal machining. That way, you won’t even need the master model. You can just create a 3D model of the jewel and make a cavity from it by using specific Boolean operations present in all CAD systems. Then, just add elements necessary for the mold halves to be joined and you can manufacture. The result is a durable mold that will serve you for tens of thousands of jewel pieces. One thing though, it is vital to manufacturing mold halves to match as close as possible. Otherwise, you’ll have a stepover and you’ll have to do a lot of postprocessing afterward.
CNC Machining of Jewelry
Jewels are usually quite small themselves and their ornaments and features are smaller still but if your machine tool and cutter are small enough, It is always possible to make jewels straight on the CNC machine. Machining silver and gold is not unheard of though they are quite soft so the clamping devices must be of similar hardness and with more contact area. The spindle speeds must be very high as well, otherwise, the metal will stick to the tool and it will be more pushed rather than cut resulting in unwanted deformations. In addition, CNC machining has some limits. Basically, it can’t cut where there is no space for the tool to operate. However, it can create intricate patterns and it can offer a very good surface finish, which will drastically cut polishing time.
Engraving Jewelry with CNC Machining
Even if you consider new rapid prototyping methods Cermet Inserts of creating jewelry unnecessary and prefer to use conventional methods. They are great as well since each jewel is hand-made. However, even if you prefer the old ways, you could still use CNC Rapid Prototyping for Jewelry. How? Well, a lot of bracelets, pendants, and rings are engraved with an intricate pattern that is hard to produce manually and CNC machining centers can be mounted with engraving tools and create perfect patterns with a tolerance less than 0,05 mm.
Cutting Diamonds with CNC
Last but not least is using CNC metal prototyping equipment with abrasive tools to create multifaceted beautiful diamonds from raw uncut stones. As you well know, raw diamonds are not those gorgeous sparkling crystals seen on our rings. They are actually quite plain. It’s the masters that make them shine. They cut off bits creating facet by facet to point Cutting Inserts out the stones’ beauty. This is a tense and time-consuming task. However, it can be done and at a considerably faster rate by implementing CNC grinding. The wheel is programmed to grind off facet to facet with a precision unreachable even by the best masters.
Conclusions
Having analyzed the main uses of CNC rapid prototyping for Jewelry, we can make a few conclusions. First, using rapid prototyping significantly decreases Jewelry production cost despite?CNC prototyping cost per hour being larger than that of manual labor. The advantage in time is so large that the overall price of the jewel made using CNC machining is smaller than paying the master for his work that he does much longer. Secondly, the quality of modern CNC machine tools is so great that no master can achieve as much. And lastly, CNC Rapid Prototyping can be implemented at almost any stage of the jewelry manufacturing process
