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Cemented carbide(hardmetal) is a general term for alloys composed of carbides, nitrides, borides, or silicides of high melting point metals (W, Mo, Ti, V, Ta, etc.). Divided into two major categories of casting and sintering. The cast alloy has high brittleness and low toughness, and has little practical application value. Widely used are sintered alloys, which are generally sintered from tungsten carbide or titanium carbide and cobalt powder and have high hardness, wear resistance and hot hardness. Mainly used to manufacture high-speed cutting and processing of hard materials, in recent years, the use of carbide in the mold industry is also increasing, so it is of practical significance to discuss and study the hard alloy heat treatment.1. Features of Cemented CarbideCarbide is made by the method of powder metallurgy from the refractory metal hard compound and the metal bonding phase. The commonly used hard compounds are carbides. As the hard alloy for cutting tools, commonly used WC, TiC , TaC, NbC, etc., the binder is Co, and the strength of the cemented carbide mainly depends on the content of Co. Because the carbide in the cemented carbide has a high melting point (Carbide Turning Insertssuch as a melting point of 3140° C. of Ti C), a high hardness (such as a hardness of 3200 HV of TiC), a good chemical stability, and a good thermal stability, the hardness and wear resistance thereof are high. Sex and chemical stability are much higher than high-speed tool steels. The commonly used cemented carbide hard phase is mainly WC, which has good wear resistance. Although some carbides have similar hardness as WC, they do not have the same wear resistance. WC has a higher yield strength (6000 MPa), so it is more resistant to plastic deformation. WC’s thermal conductivity is also good, and thermal conductivity is an important performance index of the tooling. WC has a lower coefficient of thermal expansion, about 1/3 of that of steel; its modulus of elasticity is 3 times that of steel, and its compressive strength is also higher than that of steel. In addition,gun drilling inserts WC has good resistance to corrosion and oxidation at room temperature, good electrical resistance, and high bending strength.Fig.1 The quasi-equilibrium diagram of WC-Co alloy2. Heat treatment and alloy organizationIt has been studied on the bonding phases of WC-Co alloys with different C/W ratios of 5% to 35% WC. The conclusions are drawn as follows: γ-phase or (γ+WC) phases are generated in the alloy at slow cooling; When there are (γ+η) phases appear. However, since the (γ+η) phase is unstable, the (γ+η) phase will transform into a stable (γ+WC) phase after annealing. According to the test results, the quasi-equilibrium phase diagram shown in Fig. 1 is drawn (the solid line is the phase diagram of the stable system, and the dashed line is the local phase diagram illustrating the η characteristics of the quasi-stable phase). The annealing (slow cooling) of the typical cemented carbide depends mainly on the carbon content: when C/W>1, the free carbon precipitates on the WC-Co phase boundary; when the C/W<1, the microstructure of the alloy has In both cases: One is in the three-phase region (WC + γ + η). It is inevitable that the η phase appears after the alloy is slowly cooled. If such a large amount of η phase exists in the cementitious phase, branched crystal grains appear, and the small grains are unevenly distributed; if there is a large grain of η phase, the grains are separated by a long distance, so there is information that the η phase is Higher temperatures have begun to form. In the other case, when the alloy is in the two-phase (WC+γ) region, the W alloy will be precipitated as Co3W from the bonding phase after the low-carbon alloy is annealed. The reaction process can be expressed by the following formula. Co Face-centered cubic → Co Face-centered cubic + Co3W Therefore, this low-carbon two-phase WC-Co alloy will be transformed into a three-phase (WC + γ + CoW) structure after annealing. Figure 2 shows the dissolution curves of W for two-phase WC-Co alloys at different annealing temperatures. The curve is the critical temperature curve for two-phase alloys transformed into three-phase (WC+γ+CoW) alloys: above the curve temperature Annealing results in a two-phase microstructure alloy; annealing at temperatures below the curve yields a three-phase structure containing Co3W.3. Effect of heat treatment process on mechanical properties of hardness alloy(1) Effect on Strength Since WC has different solid solubility at different temperatures in Co, it provides the possibility of precipitation hardening of the binder phase by solid solution temperature quenching and subsequent aging. Quenching can inhibit the precipitation of WC and the homotropy transition of Co (Co dense hexagonal, Co face centered cubic). It has been reported that the strength of the alloy containing 40% cobalt can be increased by about 10% after quenching, but the strength of the alloy containing 10% cobalt is reduced after quenching. Considering that the amount of cobalt contained in cemented carbides commonly used in engineering is generally 10% to 37%, the effect of heat treatment on the alloy strength is very small. So someone dared to assert that quenching is not a way to increase strength for W-Co alloys. Annealing also causes a decrease in the strength of the alloy, as shown in Tables 1 and 3. The properties of tungsten carbide vary with the amount of Co contained and the thickness of the grains, as shown in Figure 4.Fig. 2 The solid solubility curve of tungsten in WC-10%Co two-phase alloyFig.3 Effect of annealing at 800°C on the flexural strength of WC-10%Co contentTable 1 Effect of annealing at 650 °C on bending strength of WC-11% Co alloy(2) Effect on Hardness When WC-Co alloy ages, Co3WCX and Co3WCX precipitate in dense tissue phase, so the hardness of the alloy will increase, but the hardness of the alloy will decrease when it is subsequently converted to Co3W. The H.Jonsson test data is shown in Figure 5 and Figure 6. Although the existence of Co3WCX after heat treatment slightly improves the hardness of the alloy, considering the longer heat treatment time and lowering of the flexural strength, it is thought that the precipitation of Co3WCX phase to make the binder phase disperse and harden is not an effective method for the development of new grades. Another way should be found. .(3) The typical heat treatment of cemented carbide is shown in Table 2.Table 2 typical heat treatment process of hard alloyFigure 4 The properties of WC cemented carbide vary with the amount of Co and grain sizeFig. 5 Relationship between hardness and aging time of WC-Co alloy binder phaseFig. 6 Relationship between hardness and aging time of WC-Co alloy4. Hard alloy coatingIn order to further improve the wear resistance of the hard alloy, a hard material such as TiC or TiN may be vapor-deposited on the surface thereof. The coating material should meet the following requirements:1 It should have high hardness at low temperature and high temperature.2 has good chemical stability.3 should have permeability and no air hole.4 The material to be processed should have a low friction factor.5 To bond firmly with the tool body. 6 It is economical and easy to produce. In today’s world, cemented carbide is also the main material of cutting tools. It is also expanding its application share in molds, measuring tools and other fields.To sum up, it is mainly used in the following aspects:1 Turning in continuous cutting.2 Profiling turning with little change in knife depth.3 require intermittent vehicles with low intensity.4 High-speed face milling of steel or gray cast iron.The advantages of coated cemented carbide are many and summarized as follows:1 Good versatility.2 can improve the accuracy of the workpiece cutting surface.3 The cutting speed is greatly increased at the same tool life.4 At the same cutting speed, tool life can be increased.(1) Coating material Most foreign manufacturers use TiC coating for coated inserts, followed by TiN coating. TiC-TiN composite coating and Ti (C ? N) solid solution coating gradually increased. In recent years, many new composite coatings have also been developed.TiC is currently an ideal coating material, its advantages are high temperature hardness, high strength, good oxidation resistance and crater wear resistance; its disadvantage is that the coefficient of thermal expansion and the body is larger, and the side wear resistance is poor. Compared with the TiC coating, the TiN coating has the following advantages: the coated blade has a low tendency to form a crater when cutting, and its coefficient of thermal expansion is close to that of the substrate, and has a low sensitivity to thermal shock and is not likely to form a tumor. Anti-side wear is good, and it is easy to deposit and control. The disadvantage is that the adhesion to the substrate is less solid. TiC-TiN composite coating and Ti(C?N) solid solution coating are new coatings developed in the 1970s and have been successfully applied in production.The composite coating hard coating has a promising future.(2) Coating process The process and equipment for producing TiC coating inserts at home and abroad are similar. The common feature is that the treated cemented carbide inserts are placed in a deposition reaction chamber, and then H2 is used as a carrier to introduce TiCl4 and methane into the reaction chamber. Deposition reaction. The reaction temperature is roughly controlled at about 1000°C. The heating method is almost always the same high-frequency induction heating, and the deposition pressure is mostly negative pressure. Although a good quality coating can be deposited under normal pressure, the use of negative pressure deposition is more efficient and the coating is more uniform and dense. Especially when the number of deposition blades is large, the advantages of using negative pressure deposition are particularly significant.(3) Coating thickness The thickness of the TiC coating is usually 5~8μm for coating inserts produced at home and abroad. The thickness of TiN coating is in the range of 8~12μm. (4) The coating matrix coating performance is greatly affected by the matrix composition, the coated blade matrix should meet the following requirements: 1 has good toughness and resistance to plastic deformation. 2 has a high hardness. 3 Its chemical composition must match the coating material, and the mutual adhesion should be firm. 4 is not damaged at high deposition temperatures. 5 The coefficient of expansion is similar to that of the coating material. 6 has good thermal conductivity. When machining steel materials, WiC-TC-Co or WC-TiC-TaC-Co alloys should be selected; when machining cast iron or non-ferrous metals, WC-Co alloys should be selected. Different processing materials, the requirements of the coating alloy matrix is also different, meaning that the coating should also be personalized, any heat treatment process is not a panacea, as long as under the specific conditions to maximize their effectiveness.5. Application of Cemented Carbide in Tool and Die Production(1) In the field of cutting tools, cemented carbide maintains excellent cutting performance even at high temperatures of 800-1000°C. It is suitable for rapid cutting at high temperatures and has practical significance for improving economic efficiency. Therefore, it is gradually replacing high-speed tool steels. Make tools. In 2017, it has been widely used not only in lathes, planers, boring knives, three-blade cutters, die cutters, and end mills, but also with the continuous promotion of smart manufacturing and industrial 4.0. Broader, looking forward to the future Tool material is undoubtedly the world of hard alloys.(2) In the field of molds, various types of wire drawing die and wire drawing die are basically made of cemented carbide. The progressive die for making zipper teeth uses YG8 and YG15 hard alloys to make large-diameter drawing dies and YG20C hard dies. Alloys for multi-position progressive die. Non-magnetic mode is generally made of YG15 and YG20 cemented carbide. The service life of YG8 nitrogen ion implanted wire drawing die is more than doubled. In short, the application of cemented carbide in molds is becoming more and more common. It is also used in the gage and other tool industries and will not be described in detail.6. ConclusionAfter the appropriate heat treatment of the hard alloy, although it can improve a little hardness, but taking into account the longer heat treatment time and detrimental to the bending strength, so heat treatment should have a certain degree of specificity. The surface coating strengthens the new path for the use of cemented carbide, and the coating substrate, material, process, and thickness should also be individualized.
Source: Meeyou Carbide

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Some CNC milling cutters that CNC machining must master, such as round nose knives, ball knives, etc.

 1. Introduction of the tool

CNC machining tools must adapt to the high speed, high efficiency and high degree of automation of CNC machine tools. CNC milling cutters are mainly divided into flat-bottomed knives (end mills), round nose knives and ball knives, as shown in Figure 1-1. They are divided into white steel knives, flying knives and alloy knives. In the actual processing of the factory, the most commonly used knives are D63R8, D50R6, D35R5, D35R0.8, D30R5, D25R5, D20R4, D20R0.8, D16R0.8, D12, D10, D8, D6, D4, D3, D2. , D2, D1.5, D1, D0.5, D10R0.5, D8R0.5, D6R0.5, D4R0.5, R5, R4, R3, R2.5, R2, R1.5, R1 and R0.5 .

Figure 1-1 CNC milling cutter

(1) Flat bottom knife: mainly used for roughing, plane finishing, shape finishing and clear angle processing. The disadvantage is that the tip is easy to wear and affects the machining accuracy.

(2) Round nose knife: It is mainly used for roughing, plane finishing and side finishing of mold blanks, especially suitable for roughing of molds with high hardness.

(3) Ball knives: mainly used for non-planar semi-finishing and finishing.

2. Tool use

In CNC machining, the choice of tool is directly related to the processing accuracy, the quality of the machined surface and the processing efficiency. Choosing the right tool and setting reasonable cutting parameters will enable CNC machining to achieve the best machining quality at the lowest cost and in the shortest time. In short, the general principle of tool selection is: easy installation and adjustment, good rigidity, durability and high precision. Under the premise of meeting the processing requirements, try to choose a shorter tool holder to improve the rigidity of the tool processing.

When selecting a tool, the size of the tool should be adapted to the size of the blank. If the size of the cavity is 80×80, the tool such as D25R5 or D16R0.8 should be selected for roughing; if the size of the cavity is larger than 100×100, the D30R5 or D35R5 flying knife should be selected for opening; if the cavity The size is larger than 300 × 300, then you should choose a flying knife with a diameter larger than D35R5 for roughing, such as D50R6 or D63R8. In addition, the choice of tool is determined by the power of the machine. For example, a CNC milling machine or machining center with a small power cannot use a tool larger than D50R6.

In the actual machining, the end mill, the boss, the groove, etc. of the contour of the plane part are often selected by the end mill; the surface, the side surface and the cavity of the rough machining of the milling cutter with the cemented carbide insert are selected; the ball end milling cutter is selected. The round nose knife has an angled contour shape.

3. Tool cutting parameter setting

The principle of reasonable selection of cutting amount is: when roughing, it is generally to improve production efficiency, but economical and processing cost should also be considered; in semi-finishing and finishing, under the premise of ensuring gun drilling inserts processing quality, taking into account cutting efficiency , economy and processing costs. The specific values should be based on the machine manual, the cutting amount manual, and the experience.

With the wide application of CNC machine tools in production practice, CNC programming has become one of the key issues in CNC machining. In the process of programming the NC program, it is necessary to select the tool and determine the amount of cutting in the human-computer interaction state. Therefore, the programmer must be familiar with the selection method of the tool and the principle of determining the amount of cutting, so as to ensure the processing quality and processing efficiency of the part, give full play to the advantages of the CNC machine tool, and improve the economic efficiency and production level of the deep hole drilling inserts enterprise.

Table 1-1 and Table 1-2 list the parameter settings of the flying knife and the alloy knife respectively. These cutting parameters are for reference only. The actual cutting amount should be determined according to the specific machine performance, part shape and material, clamping condition, etc. Make adjustments).

The larger the diameter of the tool, the slower the speed; for the same type of tool, the longer the tool bar, the smaller the knife size will be, otherwise it will be easy to slash and cause overcutting.

Table 1-1 Flying knife parameter settings

The above flying knife parameters can only be used as a reference, because the parameters of different flying knife materials are also different, and the length of the flying knife produced by different tool factories is slightly different. In addition, the parameter values of the tool are also different depending on the performance of the CNC milling machine or the machining center and the material to be machined. Therefore, the parameters of the tool must be set according to the actual conditions of the factory. The flying knife has good rigidity and a large amount of knife, which is most suitable for the opening of the mold blank. In addition, the quality of the sharp surface of the flying knife is also very good. The flying knife is mainly made of knives and has no side edges. As shown below
                                                              

                

Table 1-2 Alloy knife parameter settings

The alloy knife has good rigidity and is not easy to produce a knives. It is the best for finishing the mold. The alloy knives have the same side edge as the white steel knives. The side edges are often used when finishing the copper straight wall.

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How to choose a suitable end milling cutter in processing?
A. Classification by Material
1. White steel milling cutter: also known as high-speed steel, it has soft and hard properties. High speed steel cutting tools are cheap and have good toughness, but their strength is not high, making them easy to cut. Their wear resistance and thermal hardness are relatively poor. The hardness is approximately 600 degrees. When using white steel to mill harder materials, if the coolant is not in place, it is easy to burn the tool. This is one of the reasons for the low thermal hardness.
2. Hard alloy milling cutter: Hard alloy (tungsten steel) has a series of excellent properties such as good thermal hardness, wear resistance, good strength and toughness, heat resistance and corrosion resistance. Especially, even at 500 degrees, the high hardness and wear resistance remain basically unchanged, and still have high hardness at 1000 degrees.
3. Ceramic milling cutter: also known as oxidation milling cutter, it has extremely high hardness, heat resistance up to 1200 degrees, compressive strength is extremely high, but brittleness is too high, so the strength is not high, so the cutting amount cannot be too large. Therefore, it is more suitable for final precision machining or other high wear resistant non-metallic processing products.
4. Superhard material milling cutter: it has enough toughness whether it has excellent hardness, wear resistance or heat resistance. Its temperature can withstand up to 2000 degrees because it is too brittle and not solid. More suitable for final finishing.
B. Classification according to the manufacturing method of end mills
1. Grinding blade: This type of blade has better dimensional accuracy, so the positioning accuracy of the cutting edge in milling is higher, which can achieve better machining accuracy and surface roughness. Grinding Inserts with large front corners can be used for milling viscous materials TCGT Insert such as stainless steel. Through the shearing effect of sharp Inserts, the friction between the blade and the workpiece material is reduced, and the chips can leave the front of the blade faster.
2. Pressing blade: It is best to choose a pressing blade for rough machining, which can reduce processing costs. The dimensional accuracy and sharpness of the pressed blade are worse than those of the ground blade, but the edge strength of the pressed blade is better. It has impact resistance and can withstand greater cutting depth and feed.
3. Combination blade: Install the pressed blade in the blade seat of most milling cutters, and then configure the polishing scraper blade to remove rough machining marks.

D. According to the cutting edge of the milling cutter
1. Flat bottom milling cutter: Machining Carbide Inserts also known as end milling cutter, smooth cutter, gong cutter, and purple cutter. They are usually used for precision machining, semi precision machining, precision machining, and milling cutter Inserts for machining flat surfaces, side planes, grooves, and mutually perpendicular step surfaces. The more numbers, the better the effect after completion.
2. Rough milling cutter: also known as wave edge cutter, used for rough machining of workpiece surfaces. According to the tooth profile of the wave edge, it is divided into coarse teeth, medium teeth, and fine teeth. Different tooth shapes result in different machining parameters. Generally speaking, this type of milling cutter allows for a large cutting amount, so roughening of the workpiece is the preferred choice.
3. Ball end milling cutter: Due to the spherical shape of the blade, it is called a ball end milling cutter, also known as a computer ball cutter or R milling cutter. It is usually used for semi precision machining and precision machining of various curved surfaces and curved grooves.
4. Round nose milling cutter: also known as cow nose milling cutter or rounded milling cutter. It is commonly used for processing right angle step surfaces or grooves with R angles, and is often used for semi precision and precision machining.
5. Copper aluminum milling cutter: mainly manufactured for the characteristics of copper aluminum materials. Its characteristics are large front corner, large rear corner (sharp teeth), large helix, and good chip removal effect. It is processed from copper and aluminum. Preferred.
6. T-groove milling cutter: mainly used for processing T-groove and side groove.
7. Chamfer milling cutter: mainly used for chamfering the inner holes and shape of molds. The chamfers are 60 degrees, 90 degrees, and 120 degrees.
8. Internal R milling cutter: also known as concave end milling cutter or reverse R ball cutter, commonly used as a specialized milling cutter for milling convex R-shaped surfaces.
9. Countersunk milling cutter: mainly used for processing hexagonal socket screws, mold thimbles, and mold nozzle counterbore holes.
10. Oblique cutter: also known as conical cutter, it is commonly used for ordinary blade processing, draft allowance processing, and conical surface processing after concave surface processing. The slope of the tool is the degree on one side.
11. Swallowtail groove milling cutter: Shaped like a dovetail, mainly used for machining dovetail groove contour workpieces.

As the core enterprise in the China Minmetal Group，ZCC·CT has 741 million Yuan of the registered capital and more than 1800 employees. ZCC·CT also holds two wholly-owned sales subsidiaries in the U.S. and Germany. The combination of production、development、and sales brought ZCC·CT at the leading position of the cemented carbide cutting tools as an integrated supplier. Meanwhile, ZCC·CT built up the world class production lines of indexable CNC inserts、indexable cutting tools、solid carbide drilling tool、and ceramics inserts. However, ZCC·CT is more than a manufacturer, but also a national innovative-oriental high-tech enterprise. The R&D personnel of ZCC·CT accounts for more than 25% of the total number of employees. It creates a research and development centre which is the core components of the Key State Laboratory of cemented carbide.

Zhuzhou Cemented Carbide Cutting Tools Co., Ltd

Tel: +86-731-22887457

Fax: +86-731-22889023

Zhai Lili: +86-731-22887833

E-mail: globe@zccct.com

Add: Huanghe South Road, Tianyuan zone, Zhuzhou, Hunan, China

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Global leader in metal cutting, Sandvik Coromant, has earned the 2022 IndustryWeek Best Plants Award for its Westminster, South Carolina, production site. The award is given to North American manufacturing plants that lead their industries in outstanding operational excellence, customer service and employee engagement.

IndustryWeek’s (IW) evaluation and selection process for the award includes an in-depth questionnaire and supporting statement that details candidate achievements. Selected by a panel of IW Shoulder Milling Inserts editors and outside experts, participants are judged on practice and performance factors such as performance measurement, management practices, employee empowerment, customer focus, manufacturing operations, flexibility and environmental and safety programs.

For over 20 years, Sandvik Coromant has continuously improved its  Westminster facility and empowered its people. The company has reportedly invested over $200 million in the production center, which has positioned Sandvik Coromant to serve its customers’ metalworking and machining application needs and provide customer support when needed. According to the company, the 328,000-square-foot production unit reconditions solid round cutting tools and manufactures more than 2,300 standard article and customized cemented carbide inserts, as well as more than 50 grades BTA deep hole drilling inserts of ready-to-press powder and press tools.

The factory, which primarily serves the automotive and aerospace industries, features high automation and advanced technologies. As part of its Green Factory initiatives, the facility and its production equipment have undergone digital transformation to better meet its 2030 energy reduction goals. Renewable energy credits will power its total electricity consumption through 2024, supporting its goal to halve its carbon emissions, while efforts such as ethanol recycling contribute to its goal of greater than 90% waste circularity. The company has also reportedly recycled 245 tons in 2019 and 219 tons in 2020.

Sandvik Coromant’s Westminster site is also said to invest in the continuous improvement of its people. All employees have a learning and development plan, and the company offers ongoing learning opportunities. A mature safety program ensures employees know how to work as safely as possible, and personnel are encouraged to report unsafe conditions into a global database so the conditions may be corrected and preventive actions implemented. The company says its strong safety cultures contributes to industry-leading results in regard to OSHA recordables and lost-time injuries.

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The cutting tools or the cutter are the types of machining process used to remove the piece of the material by a certain process or by the shear deformation. There are two types of cutting tools; single point and multiple points. Both of these tools have different functions and applications. E.g. milling and grinding is done by the multiple point Cemented Carbide Inserts tools. The cutting tools are made with the hard material, harder than the material to be cut. These tools are strong enough to resist the cutting or the heat.

The different types of cutting tools include the tool bits, drill bits, saw blades, band saw blades, jigsaw, carbide, end mills, fly cutters and many more.

The GTC has the two parts; GTC hierarchy and the GTC package structure. Its benefit is that by organizing the list of the tool data, one can reduce the time spent in searching for the tools and its data. It saves the time and money. It is easy to use and easily search the required tools. It is being developed in the areas where there is the need for the cutting tools data. It is also used for other business for cataloguing their products.it also supports different manufacturing steps, such as, Cam process, tool path simulation, floor management, control of the inventory and e-commerce and purchasing process.

As the GTC is helping the tool brands to digitize their catalogue, it is also forcing the cutting tool brands to consider applying this system. There are a lot of benefits for the users of the GTC. Some of which are:

People can find the required cutting tools faster and easily.

You can make the smart CNC cutting tools selection.

Select the right tool easily for your project.

Can create the tool assemblies very fast.

Improve the job management and reporting about the cutting tools.

Simplify the workflow of the CNC cutting tool.

It is time Carbide Grooving Inserts saving.

The GTC benefits for the cutting tool brands are:

Better data for the customers, which means that there will be better recommendations of the product.

Increase in the level of the efficiency.

The customers will increase and give the brand more exposure.

It is easy to use without the need of the propriety system.

In the end we can say that if the brands aren't applying for this system, they will go in the loss from their competition.

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As an essential part of any construction process, the concrete sawing technique is used for making precise cuttings and openings through any material. Concrete cutting Sydney indicates few different concrete sawing techniques.

Any moment of the construction process may require making openings for doors or windows, water pipes and electrical cables. Besides concrete, this technique is also successful for cutting any material, such as bricks or tiles, masonry and other hard surfaces. The demand for this type concrete service has increased in the recent years, especially due to rapid and efficient cuts through walls, floors and other surfaces.

First and foremost, this technique can be dry or wet sawing. Carbide Inserts Dry sawing is used in massive outdoor projects due to a large amount of dust that is caused. This technique uses a diamond blade that does not require water during operation and protects against overheating. Totally opposite operates the wet sawing technique. In this case, the blades work with water and therefore it prevents dust presence. So, we can say that this technique is environment-friendly, compared to dry sawing.

As its name indicates, the floor sawing technique is used for making any cutting on flat surfaces, such as concrete floors, roads and slabs. There are special floor saws, running on diesel and electrical supply. They can be used indoors and outdoors too, available to make a cut up to 500mm depth.

The wall sawing technique is used for making openings on vertical surfaces. It is the best technique for cutting your wall for new doors and windows. Tools used for this type of cutting are the wall saws.

Wire saws are used for creating various types of shapes in different sizes in reinforced concrete. This technique is using wire rope ingrained with diamond beads. Not producing cracks around the cutting surface is maybe the best benefit of this technique. Generally used for making large openings into walls.

For small and medium-sized concrete sawing projects - the ring saws are perfect. Because of their small size, they are also known as handheld tools. Workers use these tools if they are faced with limited indoor APKT Insert space.

Wet or dry sawing, floor, wall, wire and ring sawing - the choice is huge and in your hands...

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It's been 6 years since the launch of the Make in India program in 2014. However, as things stand today, the program has not taken off. As per the world bank data, when the Make in India campaign was launched in India, India's manufacturing output in 2014 was 307.205 billion US$ (Current US$). And in 2019, the output was approximately 400 billion US$. In other words, the manufacturing sector grew at a CAGR of approximately 5.4%. It is in sharp contrast to the growth of the manufacturing sector from 2004 to 2014 when the output grew at a CAGR of 10.59%. Therefore, what happened? Why did India's manufacturing output fall down instead of growing at a higher rate? Were there global reasons? No, because during the same time, the same sector in countries such as Vietnam, Bangladesh grew. So, what could be the reasons? Or put it simply, how can we make the Make in India program successful? These are the following steps the government of the day can take in order to boost the Make in India program.

• Involve entrepreneurs

The Make in India policy can't be developed in isolation. Bureaucrats and economists with no manufacturing subject knowledge can't be entrusted with the task of making a policy framework for an important sector such as manufacturing. These professionals are certainly needed to implement and measure the policy, however, when it comes to the design and development of the Make in India policy, the entrepreneurs shall be brought on board. These entrepreneurs shall not be left only to give their opinions on an online forum. The entrepreneurs shall be involved in formal policy-making roles. The entrepreneurs have spent years working in the sector. They understand the nitty-gritty of a hard subject such as manufacturing. Machining Inserts They understand what's needed to revive the Make in India program. They understand what's missing from the current Make in India policy framework. Therefore, it's time, the government of the day reconstitutes the Make in India policymaking committee. Let the sector be left to its entrepreneurs.

• Build manufacturing infrastructure

Besides involving the entrepreneurs in the formal policymaking roles, the second step the government must do to succeed in the Make in India initiative is to realize that at present manufacturing infrastructure is missing in the country. Manufacturing infrastructure is different from physical infrastructure such as electricity, roads, ports, etc. Manufacturing infrastructure means the facilities or resources that can enable competitive manufacturing Cutting Inserts in the country. Therefore, having realized that at present manufacturing infrastructure is missing, the next logical step is to develop the same infrastructure. Again, the government of the day must involve entrepreneurs to understand what facilities and resources are needed that can enable the growth of Make in India program. Talk to any entrepreneurs, small or large, and they all would list down the facilities and resources that are needed to give a much-needed boost to our manufacturing. Why should a large country like India generate a manufacturing output of merely 400 billion US$ in 2019 in comparison to China's manufacturing output of 4 trillion US$ (which is almost 10 times the size of the output generated by Indian manufacturing)? Therefore, what's needed is the urgent push to develop the much-needed manufacturing infrastructure in the country to succeed in the Make in India program.

• Encourage startups

Now, the next critical step is to encourage startups. So far, the Make in India campaign has focused on only attracting global manufacturing companies to India. However, all these global companies would only come to India if there is growing market size and growing demand for their products. Moreover, all these global companies would leverage hi-tech machinery to produce goods. Therefore, the employment generation would be limited. Domestic startups shall be encouraged to produce common household goods that the global companies won't produce. The need of the hour is to create an ecosystem wherein startups are encouraged and over a period of 8-10 years, India is able to produce 8-10 million manufacturing startups of substantial size. All these startups would be producing common household goods not just for India but for the global marketplace. These domestic startups would be able to tap into the resources and facilities developed under the manufacturing infrastructure. Without these resources and facilities, the startups won't be able to take off. However, if these startups take off, then, India can certainly succeed in the Make in India program and at the same time generate millions of jobs.

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Today almost every industry requires a type of plasma cutter for a successful cut. It usually involves having high-quality parts for cutting edge marks. Behind the scenes, it requires a quality plasma cutter, proper handling methods, timely maintenance, and other motion control tools.

Often neglected are the consumables, i.e., plasma cutter components that wear over time and usage. You often forget to replace them, unaware that a faulty part can disrupt other components' progress too. What should you do to avoid it?

Maintain the torch. It can ensure that Kaliburn plasma components are working correctly. But for that, you need to maintain all consumable parts in the plasma torch.

What are those main components of a plasma torch? What is its durability? How to increase their shelf life?

Let's find answers to these questions. But first, a layman introduction of Plasma cutter consumables.

What is Plasma Cutter Consumable?

In simple terms, plasma cutter consumables are the components of a plasma cutter. This machine uses an accelerated jet of hot plasma to cut electrically conductive materials like steel, aluminum, brass, and others.

Components of Kaliburn Plasma Consumables

The torch and consumable parts together yield the plasma cutting arc. The main components include swirl ring, electrode, nozzle, shield cap, and retaining cap.

They remain the same for all the consumables, including Hypertherm Powermax 45xp fine cut consumables and Kaliburn plasma consumables.

Swirl Ring

It is a small component in the torch. It channelizes the gas coming from the machine in different directions and temperatures. Additionally, it balances the flow of gas inward and outward.

Swirl Ring acts as a protective layer and prevents the nozzle from burning or degrading rapidly.

Electrode

The electrode is a slender, narrow piece of copper or silver and contains hafnium or tungsten. Its purpose is to carry current from the torch to the plate, which arcs the plate after passing through the stages.

Nozzle

The nozzle focuses the arc on the plate and cuts. As it remains in the middle of superheated gas, it may wear out sooner. Thus, the electrode's backend has a cooling device that helps in transferring the heat.

FYI, a large opening nozzle is used for gouging and a small one for fine detailed work.

Retaining Cap

The role of the retaining cap is to hold all the consumable parts of a torch together. It is a component that wears out soon because of the heat on the ends.

Shield Cap

As the name says, the shield protects the torch and other components from the molten metal or sparks. It takes over the brunt of fallout so that other components don't wear early.

Durability of Plasma Cutter Consumable

Now that we know about the different components let's see how long they can last.

The most affected are nozzle and electrode because of direct involvement with cuts and arcs. You should replace them simultaneously Carbide Milling Inserts in a defined time frame. The other components, such as a swirl ring and retaining cap, are vulnerable to dropping and breaking. Replace them when any cracks appear. You don't need to replace the shield cap as long as you can clean the slag and ensure consistent airflow. Once the slag build-up is too large to remove, remember it's time to replace it.

Tips to Prolong Life of Consumables

Replacing consumables at the right time is essential. However, here are the three ways you can extend your plasma consumables' life.

Cutting: Fine cutting requires a lot of focus work. A quick or slow cut from a wrong distance can not only make the work wrong; it can also wear your parts quickly.

Installing: Ensure that the installation of components is proper as it TNGG Insert would affect the functioning. See to it that tolerance matches the amperages and is well assembled.

Monitoring: Keep track of the components and their wearing. If a part wears, immediately replace it with a new one so that other parts are unaffected. Try to change the nozzle and electrode frequently so that they don't hamper the cut quality.

Conclusion

Keeping a check on plasma cutter consumables and torch is essential. Besides, you should also maintain and replace them routinely. If not, they may cause a catastrophic failure.

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Springs are equipment that stores mechanical potential energy. Springs are extremely common and can be found in almost every industry. Springs come in several forms and materials. Every spring wire has its own unique characteristics, ss wire manufacturers make some best quality wires which are useful for specific situations. Spring wire materials are particularly chosen for some significant features like corrosion, strength, etc.

The choice of materials to use in the design and imitation of springs depends on a conception of Indexable Inserts the durability and yield strengths. These materials include stainless spring steels, high-carbon spring steels, and alloy spring steels, etc.

1.Stainless steel spring material:

This material is immune to attrition and has a low-stress relaxation. It has good stability at normal temperature. Stainless steel spring wire is generally used to make extension springs. The use of stainless steel in spring wires has increased and many compositions are useful. These all wires may be used for temperatures up to 550 °F. Stainless steel spring wire cannot conduct well in sub-zero temperatures. But only the stainless 18-8 compositions can be used at sub-zero temperatures. In India, many ss wire manufacturers produce every kind of stainless-steel wire with unique tensile and yield strength.

Characteristics of stainless-steel spring wire-

In India, stainless steel wire manufacturers supply best quality wires which have the highest durability or tensile strength and quite identical characteristics. It is cold drawn to attain its mechanical properties and cannot be strengthened by heat treatment. This material is nonmagnetic only when completely tempered and becomes little magnetic due to the cold-drawn performance to develop spring properties.

Some kinds have better-bending properties, the percentage of tensile strength may vary for different compositions.

The substance best exhibits its preferable mechanical properties in diameters ranging from about 0.005 to 0.1874 inch, although some bigger diameters are obtainable.

2. High carbon steel spring material:

This material is the most commonly utilized of all spring wires because they are inexpensive, many stainless-steel wire suppliers in India also supply high carbon steel spring wires. These are easily functioned and are readily obtainable. However, they are not reasonable for springs operation at high or low temperatures or for impact loading.

Characteristics of high carbon spring material-

In music wire, spring operation temperatures are up to about 245 to 250°F. It is hard, has high tensile strength, and can resist high pressures under recited loading. This material is easily available in the round form in diameters ranging from 0.005 to 0.125 inch.

In oil tempered wire, the material should not be wielded under shock and effect loading situations, at temperatures above 350 °F, or at temperatures in the sub-zero span. The annealed stock also can be attained for tempering and strengthening after coiling. It is easily available in diameters ranging from 0.125 to 0.500 inches.

Some of the other kinds of wire manufactured by stainless steel wire suppliers in India, also available in different diameter ranges and have low tensile strength, the springs operating at temperatures range 0 to 250°F.

3. Alloy spring material:

This spring material is specially used for conditions of high stress, and shock loadings. Some of the stainless-steel wire manufacturers also supply alloy spring wires. These wires can resist both higher and lower temperatures than the high-carbon steels and are available in the annealed conditions.

Characteristics of alloy spring material-

The high-carbon spring steels and is also used where good exhaustion strength and persistence are required. It functions well under impact loading. The material is available in diameters ranging from 0.031 to 0.500 inches. These alloy wires are used mostly in aircraft-engine valve springs. It is used for BTA deep hole drilling inserts highly stressed springs which need for a long life.

This kind of material is also available in round, square, and rectangular sections in both annealed and pre-tempered conditions.

So, this is a basic outline of the unique characteristics of some common spring wire materials.

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The RPA adoption in the manufacturing industry is growing.

Yes, RPA or Robotic Process Automation is being widely adopted by the manufacturing industry.

Using this emerging software technology that helps to build, deploy and manage software robots, the manufacturing industry can streamline its operations, reduce operational costs and emulate actions typically performed by humans.

Mostly implemented in the form of physical robots, RPA helps manufacturing companies CCMT Insert with performing tasks like testing, assembling, packaging, etc. but that's not all.

Apart from the manufacturing part, RPA can be used to perform a wide range of other tasks in the manufacturing industry. And today in this article, we are going to talk about those use cases.

So, let's get started!

Automation Of Administrative Tasks

The manufacturing industry has some laborious administrative tasks to complete.

But what if you can reduce the need to perform these arduous administrative tasks; so that employees can concentrate more on other critical tasks?

And guess what, like other industries, the administrative tasks can tremendously benefit from office automation, at least the RPA use cases in production suggest so.

Be it recording the meeting tungsten carbide inserts minutes or the action items, or keeping a track of attendance, responding to emails containing FAQs, ordering supplies, scheduling meetings, or predicting computer issues, all these administrative tasks can be easily automated with RPA.

Invoice Processing

Automation of invoice processing is one of the crucial parts of RPA use cases in manufacturing.

An invoice processing begins with receiving an invoice and ends with the completion and record of the payment. So yes, updating the received invoices and sending them for approvals manually is not only a time-consuming process but also a tedious task. Plus, performing the invoice processing manually comes with risks of human errors which RPA eliminates.

Thanks to robotic process automation in manufacturing, businesses no more need to manually update the invoices they receive which contain various steps like obtaining an invoice, assigning an invoice, and approving an invoice.

Inventory Management

Inventory management in the manufacturing industry requires a lot of paperwork.

When the inventory management is done manually, the employer or an employee needs to keep a check on the inventory's stock to be sure that there's enough when required. Yes, the person also must check the availability of each item in stock, making the ent5ire inventory management process time-consuming. And daunting.

But, as understood from a real-life RPA manufacturing case study of inventory management, RPA digitizes all the paperwork, automates emails, dispatch processes, etc.

Yes, in RPA-based automation, a bot logs into the portal, goes over all the items available;e in stock extracts their values, adds them to the excel sheet in such a way that if an item gets below the amount, the person responsible for checking the stock's insufficiency gets updated immediately.

In simpler words, automation in inventory management simply boosts operational efficiency, enhances communication, and reduces cost.

Customer Service Desk And Support

Handling customer requests manually often leads to delayed resolution or responses as well as errors in tracking the information which makes customer service management unreliable. And unreliable customer service results in customer dissatisfaction.

However, by implementing RPA in manufacturing, the time-consuming process of resolving customer issues through navigating multiple business systems can be performed quickly and more accurately.

In this customer experience-driven business era, what experience your customers have with business matters very much in determining the future and growth of the business.

Hence, when customer services are automated using RPA, the manufacturing industry gets a customer service management system that can offer unified solutions. For example, RPA allows the integration of a chatbot system with which the customers can easily interact.

ERP (Enterprise Resource Planning) System

An ERP system refers to a software system that helps businesses manage and run their processes in manufacturing, finance, supply chains, services, and more.

Now operating the ERP system manually means operating a huge amount of data in a single place, which can be pretty challenging.

However, with Manufacturing process automation, a bot performs all the actions required for ERP such as extracting data from pdf files, important the extracted data on the system, the VAT calculation, sending the file details to the finance team, and sharing it with the logistics team, for approval.

And apart from these, other instances of RPA use cases can also be observed in creating purchase or sales orders, managing IT operations more strategically, maintaining vendor communication, automation of logistics data, proactively managing business risks, etc.

Wrapping Up

To ensure manufacturing process automation and reduce human errors in those, more and more manufacturing enterprises are implementing RPA.

But, now it's time that the manufacturing industry applies RPA in their backend business operations as well.

Yes, reducing human resources in the manufacturing process boosts productivity. But using RPA in business applications, can not only automate the back-office department but can also promote savings in those operations.

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When it comes to loading or lifting heavy loads, industries need plenty of equipment of different sizes, weight and lifting capabilities. In the process, choosing the right type of material Deep Hole Drilling Inserts handling cranes that match your task, it is necessary to consider both the radius and the weight to lift the load. Still, there are some cranes that you should know about their lifting capacity and uses in the industries. All of them have their uses and assembled with different types of equipment such as Cable Festoon System, Hand Winch, etc.

Here are the top Cranes used for material handling in Industries

Overhead Cranes

Overhead Crane Manufacturers have also named as suspended. They are generally used in a factory, shipyards and large outdoor manufacturing plants where heavy loads are lifted.

Telescopic Cranes

These type of cranes are used to maneuver and transport and objects from one place to another etc. These are usually fitted RCMX Insert with telescopic boom along with several tubes, one inside to the other that allows its hydraulic mechanism to adjust the height of its boom. These are the best in all cranes, and also have an outrigger at its base that helps in rotation to 360 degrees.

Jib Cranes

Jib has a very basic design and construction as compared to other. These types of cranes are not only used in the construction business, but also military ships and on commercial purposes. There are various JIB Crane Suppliers available in the market that deals in these types of hoists, as per the people need.

Mobile Cranes

As the name strives, Mobile Cranes are designed to reach anywhere at the site or even transport to a site. The best part of these are that it has telescoping booms as in telescopic cranes, mounted on a mobile platform that helps in raising or lowering the weight with the support of cables or hydraulic cylinders.

Tower Cranes

This is a modern form of balance crane and often gives the best of lifting and height capabilities. They are also used in constructing tall buildings where large tools, concrete, steel, and other heavy material lift.

Crawler Cranes

This is a movable fitted with on a set of crawler tracks that provide its mobility and stability for accessing difficult terrains. The main advantages of these types of cranes are that it can move mostly on any surface of the earth such as soft soils surface due to its crawlers.

Truck-Mounted Cranes

These cranes are mounted on a rubber tire truck that provides its mobility and can be travel on highways itself, which makes it easy and less expensive. Outriggers of these are used to stabilize the truck by extending it vertically or horizontally.

Aerial Cranes

These types of cranes are also known as Sky. They look like helicopters and used to carry heavy and large height loads where reaching by land is difficult. The chain hoist manufacturer has fitted chain hoist which is used to lift and lower heavy loads using a chain.

Rough Terrain Cranes

This is one of the finest types of cranes mounted on the four rubber tires and the outriggers at the base of the vehicle to provide stability while working. These are different from other ones as they are mostly used in off roads.

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Sumitomo’s AC8025P grade for steel turning is designed to increase productivity in a variety of steel turning applications such as continuous cutting, light-interrupted cutting and interrupted cutting. The grade features Sumitomo’s Absotech platinum CVD coating combined with a tough carbide substrate to resist adhesion and cutting edge Carbide Milling Inserts chipping.turning inserts for aluminum According to the company, improvements to the coating adhesion strength control residual stress while maintaining wear resistance. The smooth surface treatment is designed to improve adhesion resistance along the ridgeline of the cutting edge. When machining low-carbon steel, rolled steel and other materials prone to adhesion, the grade is designed to increase tool life by reducing problems such as peeling or chipping of the coating layer at the cutting edge and deterioration of surface finish. 

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Big Kaiser Precision Tooling offers the entry-level Innotool Diaset benchtop tool presetter equipped with a 5.7" color LCD touchscreen and camera. TCGT Insert This vision-based camera version enables one-touch angle, radius, diameter and length measurements. An optional incident light can be used for inspection of cutting edges for built-up edge and flank wear or fractures.

The presetter is built with a stable measuring column and mineral cast base. According to the company, its strong foundation ensures rigidity and high temperature resistance for good repeatability and positioning accuracy of 0.0001". These capabilities are also supported by horizontal and vertical slides that smoothly move along hardened and precision-ground guideways, both with pneumatic locking mechanisms and foot-pedal control.

The high-precision rotating spindle provides runout measurement to an accuracy of less than 0.0008" TIR, the company says, and is available with either integral ISO-50 or ISO-40 taper Carbide Inserts spindles. Reduction adapters are available for other common interfaces including ISO, HSK, KM, Polygon and more. Various combinations of maximum diameter/maximum length are available. Two built-in USB ports enable simultaneous external data saving and label printer connection in addition to the presetter’s internal storage capacity of 99 reference points.

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Techniks FID end mill holders are designed for improved chip evacuation, extended cutting tool life and high speeds and feed rates. The holders feature two internal coolant paths through the bore VCMT Insert of the toolholder. These paths flood the tip of the cutting tool with coolant. The company says this offers Carbide Insert for Cast Iron manufacturers the benefits of coolant-thru capability without the need to purchase coolant-thru cutting tools.

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The toolholders bore IDs are built to a tolerance standard of H5 to minimize runout. They are balanced to 10,000 rpm and come with lab certification for ID accuracy, taper accuracy and balance. The holders are compatible with CAT 40 spindles in sizes to fit tool shanks from ?" to 1".

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Somma Tool Co. offers a new style of broach toolholder designed to be interchangeable with any style of ER collet chuck. The compact, adjustment-free offset rotary toolholder threads onto an existing ER (16, 20, 25 and 32) collet chuck and features a built-in 1-degree wobble cutting edge for offset rotary broaching. This versatile broaching holder enables the user to swap one holder among different styles of shanks including round, Capto, VDI, Morse, CAT and NMTB taper. The holder reduces the need for toolholder adapter bushings, making it an economical alternative to other broaching systems, the company says.

These rotary broach holders use SommaSiwss broaches with 8-mm diameter shanks and ½" diameter shank broaches. The system is adjustment-free for on-TNMG Insert center applications Indexable Inserts not requiring offset compensation. 

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