Advantages of Diamond Coated Inserts

Accuracy: The diamond coating is very thin, but very hard, and tools don’t change significantly in size during their life. For instance, the radius on an endmill will change by about 10 microns (0.0004") from when new to the point that it is worn out.

Speed: Diamond tools can typically be run at two to three times the surface speed of carbide tools.

Dry cutting: Diamond tools can often convert an operation from wet to dry machining, providing a significant saving in overall machining costs.

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Machining Ferrous Materials with Diamond

Why can't you machine ferrous metals with diamond?

Diamond is unaffected by almost every other chemical or compound in nature. One exception is hot iron. The carbon atoms in diamond will dissolve into the iron, quickly eroding the diamond surface. Iron wheels are used for polishing natural diamond.

TaeguTec Insert Grades

Announcement

www.pgstools.com has just added a TaeguTec Insert Grades Chart. This insert grade chart lists speeds and feeds for TaeguTec Inserts as well as a list of TaeguTec Insert Grades.

Machining Green Ceramic

CVD diamond tools provide a wear life gain of 25x to 100x

over uncoated carbide when machining green ceramic

The abrasive nature of green ceramic severely limits the life of carbide tools, necessitating frequent tool changes. The extended wear life of diamond tools, on the other hand, permits many machining operations to be performed with minimal or no supervision. The very gradual wear of a diamond tool also makes it much easier to maintain workpiece accuracy, thereby minimizing any need for slow and expensive machining after firing. Another advantage of diamond tools is faster machining — speeds can be increased 10 to 20%, and feeds up to 100%.

Machining Waspaloy

First of all What is Waspaloy?
Waspaloy is a precipitation hardening, nickel-based alloy which has been used in elevated temperature applications. The alloy has been used for gas turbine engine parts which require considerable strength and corrosion resistance at temperatures up to 1600°F (871°C). Waspaloy is usually vacuum-induction plus consumable electrode remelted.

Waspaloy Corrosion Resistance?
Waspaloy has excellent resistance to corrosion by combustion products, encountered in gas turbines and aircraft jet engines, at temperatures up to 1600°F. Intergranular oxidation occurs at temperatures above 1600°F.

Waspaloy Machinability
Waspaloy is difficult to machine in any condition of heat treatment. The air-cooled, solution treated condition is best for most operations (this is Rockwell C 30 partially aged). Rigid, well-powered machines are required for best results. Cemented cardide tools are preferred for most operations and care must be exercised to obtain positive cuts at all times, otherwise "glazing over" and work hardening of the surface will occur.
The following tool geometry, feeds, and speeds have been found satisfactory for lathe turining:
0° back rake
6-8° side rake
5-8° clearance (end and side)
15-20° lead angles may be used to reduce feed pressure on roughing cuts.
Speeds of 35/50 sfm will feeds of 0.005/0.15" per revolution are recommended. Slower speeeds and greater feeds should be used for roughing cuts and faster speeds and lighter feeds for finishing cuts. Better tool life will be obtained by machining in the solution treated condition; however, a smoother finish can be obtained by machining in the fully aged condition.

Carbide Inserts Versus HSS

One of the main benefits of using carbide inserts versus high speed steel (HSS) is that carbide is able to withstand much higher temperatures. Some times carbide will allow the machine operator to permit faster speeds increasing productivity. Addtionally carbide inserts may leave a better finish when tested against HSS. Carbide is typically considered to be more brittle than other materials. This can result in more frequent chipping or breaking. To compensate for this most manufacturers make tools that allow for inserts that fit within an insert holder. This allows for easy replacement of the carbide inserts at low costs since the entire tool does not need to be replaced. Today the majority of mills, end mills and lathe tools utilize carbide inserts.

IPM (Inches Per Minute) Calculator

pgstools.com now offers an online calculator for IPM (Inches per Minute).