In the field of industrial processing, cemented carbide cutting tools have become indispensable assistants for machining materials like metal, stone, and wood, thanks to their high hardness, wear resistance, and high-temperature resistance. Their core material, tungsten carbide alloy, combines tungsten carbide with metals such as cobalt through powder metallurgy, endowing the tools with excellent cutting performance. However, even with superior properties, improper use not only reduces processing efficiency but also significantly shortens tool life and increases production costs. The following details common mistakes in using cemented carbide cutting tools to help you avoid risks and maximize tool value.
I. Incorrect Tool Selection: Neglecting Material and Working Condition Matching
Cemented carbide cutting tools come in various types, each suitable for different materials and processing scenarios. For example, tools with higher cobalt content have stronger toughness and are ideal for machining ductile metals, while fine-grain cemented carbide tools with higher hardness are more suitable for high-precision cutting. However, many users focus only on brand or price when selecting tools, ignoring material characteristics and processing conditions.
- Error Case: Using ordinary cemented carbide tools for machining high-hardness alloy steel leads to severe tool wear or even edge chipping; or using roughing tools for finishing, failing to achieve the required surface finish.
- Solution: Clarify the hardness, toughness, and other characteristics of the workpiece material, as well as processing requirements (e.g., cutting speed, feed rate). Refer to the tool supplier’s selection manual and consult professional technicians when necessary to choose the most suitable tool model.
II. Improper Cutting Parameter Setting: Imbalance in Speed, Feed, and Depth of Cut
Cutting parameters directly affect tool life and processing quality. Although cemented carbide tools can withstand high cutting speeds and feed rates, higher is not always better. Excessively high cutting speed raises tool temperature sharply, accelerating wear; too large a feed rate may cause uneven tool force and edge chipping; and an unreasonable depth of cut affects processing accuracy and efficiency.
- Error Case: Blindly increasing the cutting speed when machining aluminum alloy causes adhesive wear due to overheating; or setting an excessively large feed rate results in obvious vibration marks on the machined surface.
- Solution: Based on workpiece material, tool type, and processing equipment, refer to the recommended cutting parameters table to set cutting speed, feed rate, and depth of cut reasonably. For initial processing, start with lower parameters and adjust gradually to find the optimal combination. Meanwhile, monitor cutting force, cutting temperature, and surface quality during processing and adjust parameters promptly.
III. Non-standard Tool Installation: Affecting Cutting Stability
Tool installation, 看似 simple, is crucial for cutting stability. If the fitting accuracy between the tool and the tool holder, or between the tool holder and the machine spindle, is insufficient, or the clamping force is uneven, the tool will vibrate during cutting, affecting processing accuracy and accelerating tool wear.
- Error Case: Impurities between the tool holder and spindle taper hole are not cleaned, causing excessive coaxiality deviation after tool installation, leading to severe vibration during cutting; or insufficient clamping force causes the tool to loosen during cutting, resulting in out-of-tolerance machining dimensions.
- Solution: Before installation, carefully clean the tool, tool holder, and machine spindle to ensure the mating surfaces are free of oil and impurities. Use high-precision tool holders and install them strictly according to operating specifications to ensure the tool’s coaxiality and perpendicularity. Adjust the clamping force reasonably based on tool specifications and processing requirements to avoid being too large or too small.
IV. Inadequate Cooling and Lubrication: Accelerating Tool Wear
Cemented carbide tools generate significant heat during cutting. If heat is not dissipated and lubricated in time, the tool temperature will rise, intensifying wear and even causing thermal cracks. Some users reduce coolant usage or use inappropriate coolants to save costs, affecting cooling and lubrication effects.
- Error Case: Inadequate coolant flow when machining difficult-to-cut materials like stainless steel causes thermal wear due to high temperature; or using water-based coolant for cast iron parts leads to tool surface rusting, affecting service life.
- Solution: Select suitable coolants (e.g., emulsion for non-ferrous metals, extreme-pressure cutting oil for alloy steel) based on processing materials and technological requirements, and ensure sufficient coolant flow and pressure to fully cover the cutting area. Replace coolants regularly to prevent contamination by impurities and bacteria, which affects cooling and lubrication performance.
V. Improper Tool Maintenance: Shortening Service Life
Cemented carbide tools are relatively expensive, and good maintenance can effectively extend their service life. However, many users neglect tool cleaning and storage after use, allowing chips and coolant to remain on the tool surface, accelerating corrosion and wear; or continuing to use tools with slight wear without timely grinding, exacerbating damage.
- Error Case: Chips accumulate on the tool surface without timely cleaning after use, scratching the tool edge during the next use; or failing to grind the tool in time after wear, leading to increased cutting force and reduced processing quality.
- Solution: Clean the tool surface of chips and coolant promptly after each use, using special cleaners and soft cloths for wiping. When storing tools, avoid collisions with hard objects and use tool boxes or racks for proper storage. When tools show wear, grind them in time to restore cutting performance. Choose suitable grinding wheels and parameters during grinding to avoid tool damage due to improper grinding.
These common mistakes in using cemented carbide cutting tools are frequent in actual processing. If you want to learn more about usage tips or industry knowledge of cemented carbide products, feel free to let me know, and I can create more relevant content for you.