Precision Mould Tungsten Carbide Machining : M2 Internal Threading

🕜 Efficiency - enhanced 67% | 📈 Quality - complete profile | ⚙️ Tool Life -improved

What makes Tungsten Carbide difficult to machine?



Tungsten Carbide is an alloy of tungsten and carbon. It is a metal-like substance and is approximately 2 to 3 times as rigid and dense as steel. Tungsten Carbide is often referred to as a Hard Metal, for it possesses very high hardness in relation to other metals. The Mohs hardness rating is around 8.5 ~ 9, and it is extremely stable that does not oxidize under normal temperatures and remains stable even in harsh environments.

The high hardness and wear resistance tungsten carbide have brought great challenges and difficulties for industrial manufacturers, especially for the machining of M2 internal thread. Generally, EDM (Electrical Discharge Machining) is the most commenly used machining process when it comes to the machining of tungsten carbide. However, it would inevitably create a white layer upon the machining surface, resulting in worse workpiece quality. The followed-up manufacturing steps to remove the white layer were needed and could be extremely time-consuming.

On the other hand, with conventional CNC machining, the strong cutting force and the constant contact between the tool and workpiece would consequently accelerate and intensify the tool wear, especially for a material as hard as tungsten carbide. The major diameter of the M2 internal thread became smaller as the thread went deeper. Eventually, the screw could not be fully locked into the thread, resulting in serious impact on the quality of product.


 

☑️ Tungsten Carbide Machining Information

 
   Tungsten Carbide Machining Information     
  Material   Tungsten Carbide
  Feature   M2 x 0.4mm_depth 3mm_internal thread
  Process   Internal Threading  
  Ultrasonic Tool Holder           HSKE40-R02-06
  Rotating Speed   30,000 rpm
  Tool Selection   Resmo RNA-DIA-M2-K8-#325 Single type thread mill  


 
HSK-E40 ultrasonic toolholder was used on the machining of tungsten carbide M2 internal threading
(Figure 1. HSK-E40 ultrasonic toolholder was used on the machining of tungsten carbide M2 internal threading)



HIT ultrasonic-assisted machining of tungsten carbide M2 internal threading workpiece
(Figure 2. HIT ultrasonic-assisted machining of tungsten carbide M2 internal threading workpiece)



 

HIT's Goal in Machining Tungsten Carbide


The goal is to successfully make an M2 internal thread on tungsten carbide with HIT ultrasonic-assisted machining technology on CNC machine tool.



 

Ultrasonic-Assisted Machining Tungsten Carbide Results

 

Tungsten Carbide M2 Internal Threading : Machining Efficiency


the machining efficiency was enhanced 67% with HIT Ultrasonic on M2 internal threading of tungsten carbide
(Figure 3. the machining efficiency was enhanced 67% with HIT Ultrasonic on M2 internal threading of tungsten carbide)

 
  • (Under the same feed per revolution) With HIT ultrasonic, both rotation speed (from 10,000rpm to 30,000rpm) and feed rate (from 20mm/min to 60mm/min) can be enhanced 3 times higher than the ones suggested by the tooling supplier.
  • The processing time of completing one internal thread was reduced to 1/3 of the processing time without ultrasonic.
  • With HIT ultrasonic, it helped reduce the cutting force under high-speed machining, which accomplished the machining of M2 internal thread on tungsten carbide.


 

Tungsten Carbide M2 Internal Threading : Workpiece Quality


the comparison of workpiece quality between HIT Ultrasonic and Without Ultrasonic on M2 internal threading of tungsten carbide workpiece
(Figure 4. the comparison of workpiece quality between HIT Ultrasonic and Without Ultrasonic on M2 internal threading of tungsten carbide workpiece)

 
  • With HIT ultrasonic, the high frequency micro-vibration allowed for intermittent contact between the tool and workpiece, which greatly helped reduce cutting heat.
  • The reduction in both cutting force and cutting heat under high-speed machining contributed to the completeness of the M2 internal thread profile.


 

Tungsten Carbide M2 Internal Threading : Tool Life


the comparison of tool wear between HIT Ultrasonic and Without Ultrasonic on M2 internal threading of tungsten carbide
(Figure 5. the comparison of tool wear between HIT Ultrasonic and Without Ultrasonic on M2 internal threading of tungsten carbide)

 
  • The optimized machining parameters (3 times higher than the ones suggested by the tooling supplier-S30,000rpm; F60mm/min) were to present the best of ultrasonic-assisted machining technology, and as an accelerated test on the tool life.
  • Under the high-speed ultrasonic-assisted machining process, the tool can complete one M2 internal thread; whereas the tool failed to complete any internal threads without ultrasonic and even appeared to have serious tool wear (obvious feed marks left on the tool).



 

HIT Ultrasonic Machining Technology Achievements


🕜 Efficiency - enhanced 67%
📈 Quality - complete profile
⚙️ Tool Life - improved




 

Tungsten Carbide Machining in Industry Application



Internal threading Tungsten Carbide is often applied in the Precision Machinery industry, especially for cutting tools, moulds and dies, high-performance mechanical wear parts, metal forming tools, cutting tips for saw blades, etc.


Tungsten Carbide is an alloy of tungsten and carbon. It is a metal-like substance and is approximately 2 to 3 times as rigid and dense as steel. Tungsten Carbide is often referred to as a Hard Metal, for it possesses very high hardness in relation to other metals. The Mohs hardness rating of Tungsten Carbide is around 8.5 ~ 9, and it is extremely stable that does not oxidize under normal temperatures and remains stable even in harsh environments.

The high hardness and wear resistance of tungsten carbide have brought great challenges and difficulties for industrial manufacturers, especially for the machining of M2 internal thread.

That was when HIT's Ultrasonic Machining Module came to help!  HIT offers a comprehensive solution in machining advanced materials.  With the assistance of HIT's Ultrasonic Machining Technology, clients stopped worrying about poor tool life due to serious tool wear caused by accumulated chips while trying to shorten the processing time.  The machining efficiency can be greatly enhanced while improving the stability in tool life.  HIT assures its clients of not only matching up with their requirements, but also achieving even better outcomes!





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