Optoelectronics (Slot) Trochoidal Milling of Tungsten Carbide

📈 Quality - smooth surface with 2x lower surface roughness | ⚙️ Tool Life - over 2x longer with better chip evacuation

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.  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.

 
 

☑️ Tungsten Carbide Machining Information

 
   Tungsten Carbide Machining Information     
  Material   Tungsten Carbide
  Feature   Slot width 2.1mm_length 50mm_depth 0.2mm
  *Material hardness HRA91.5
  *Workpiece size 70*50*10mm
  Process   Trochoidal Milling
  Ultrasonic Tool Holder    HSKE40-R02-06
  Optimized Parameters   S 30,000rpm; F 500mm/min; Ap 0.04mm
  Tool Selection   #200 Φ1.5mm Electroplated diamond grinding tool  

 
HIT HSK-E40 ultrasonic machining module was used on slot trochoidal milling of tungsten carbide
(Figure 1. HIT HSK-E40 ultrasonic machining module was used on slot trochoidal milling of tungsten carbide)


 

HIT's Goal in (Slot) Trochoidal Milling of Tungsten Carbide


The goal is to do (slot) trochoidal milling of tungsten carbide with the electroplated diamond grinding tool.  With HIT ultrasonic, it was expected to mitigate the tool marks, reduce surface roughness of the slots, and prolong tool life.





 

Ultrasonic-Assisted (Slot) Trochoidal Milling of Tungsten Carbide: Machining Results

 

Tungsten Carbide (Slot) Trochoidal Milling: Surface Quality

HIT ultrasonic-assisted slot trochoidal milling of tungsten carbide achieved better surface quality
(Figure 2. HIT ultrasonic-assisted slot trochoidal milling of tungsten carbide achieved better surface quality)

 
  • With HIT ultrasonic, the high frequency micro-vibration allows the tool to constantly lift from workpiece.  This brings better inflow of cutting fluid, offering better cooling effect and easier chip and carbonized diamond powder evacuation.
  • Under the same cutting parameters, with HIT ultrasonic, it helped reduce the surface roughness of the slots.  There was no obvious tool marks or scratches left on the surface compared to that without ultrasonic.




HIT ultrasonic-assisted slot trochoidal milling of tungsten carbide helped reduce surface roughness, achieving nearly 2x better surface quality
(Figure 3. HIT ultrasonic-assisted slot trochoidal milling of tungsten carbide helped reduce surface roughness, achieving nearly 2x better surface quality)




 

Tungsten Carbide (Slot) Trochoidal Milling: Tool Life

HIT ultrasonic-assisted slot trochoidal milling of tungsten carbide brought better chip evacuation, preventing chips or carbonized diamond powder stuck on the tool
(Figure 4. HIT ultrasonic-assisted slot trochoidal milling of tungsten carbide brought better chip evacuation, preventing chips or carbonized diamond powder stuck on the tool) 

 
  • Better chip and carbonized diamond powder evacuation helps reduce friction between tool and workpiece, which then reduces the cutting forces.  This not only prolongs the tool life, but also helps enhance over 2x higher material removal volume.




HIT ultrasonic-assisted slot trochoidal milling of tungsten carbide helped reduce cutting forces and prolonged tool life, achieving over 2x higher total material removal volume
(Figure 5. HIT ultrasonic-assisted slot trochoidal milling of tungsten carbide helped reduce cutting forces and prolonged tool life, achieving over 2x higher total material removal volume)




 

HIT Ultrasonic Technology Achievements in (Slot) Trochoidal Milling of Tungsten Carbide



📈 Quality -  smooth surface with 2x lower surface roughness
⚙️ Tool Life - over 2x longer with better chip evacuation


 

Tungsten Carbide (Slot) Trochoidal Milling in Industry Application



(Slot) Trochoidal Milling of Tungsten Carbide is often applied in the Optoelectronics industry, especially for optical precision moulds.


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.  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.


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 maintain great surface quality.  The surface quality 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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