Precision machinery [ATC04] Tungsten Carbide Grinding & Threading

🕜 Efficiency - processing time of Threading increased 83%, processing time of Grinding increased 60%, and processing time of the entire process increased 58% | 📈 Quality - (Threading) remained consistent, (Grinding) surface roughness from Ra > 0.8μm to the average of Ra < 0.1μm | ⚙️ Tool Life remained stable

 

What makes Tungsten Carbide difficult to machine?


Tungsten Carbide, also known as Cemented Carbide, is an alloy of tungsten and carbon.  It is approximately 2-3 times as rigid and dense as steel, and it is highly resistant to deformation at both extreme low and high temperatures.

This material is incredibly hard and difficult to machine, since most of the machine bits and tools are made of Tungsten Carbide themselves.  Generally, it is impossible to be machined by traditional machining process.  Though it can be machined by special tools, such as PCD, CNB, and ceramic tools, these cutting tools lose their sharpness easily due to the extreme hardness of Tungsten Carbide.


☑️ Tungsten Carbide Machining Information
 
  Tungsten Carbide Machining Information
  Material   Tungsten Carbide
  Dimensions   Threading : M10 x 1.5P mm
  Grinding : h-shape processing
  Methods   Threading; grinding
  Tool Holder   HSKA63-GEN-10
  Machine Tool Type   5-axis gantry type
  Rotating Speed   12,000 ~ 14,000 rpm
  Integrated System   CTS; ATC; CNC Automation




 



(Figure 1. ultrasonic machining on Tungsten Carbide workpiece)


(Figure 2. close-up of ultrasonic threading on Tungsten Carbide workpiece)


(Figure 3. close-up of ultrasonic h-shape grinding on Tungsten Carbide workpiece)

 

HIT's Goal in Machining Tungsten Carbide


To compare HIT's ultrasonic effects with the traditional EDM on threading and grinding on Tungsten Carbide.
 


Ultrasonic-Assisted Machining Tungsten Carbide Results


The processing time of threading on Tungsten Carbide was around 52 minutes and 34 seconds. (less than 1 hour)
The processing time of h-shape grinding on Tungsten Carbide was around 3 hours 37 minutes and 50 seconds. (less than 4 hours)
In the traditional EDM process, the entire process normally took more than 12 hours to complete machining these features on Tungsten Carbide.
With HIT's Ultrasonic Machining Technology, the entire process could be completed within 5 hours.

The surface roughness (Ra) before processing was around 0.936μm.
After processing, the Ra ranged from 0.036 to 0.174μm, with the average of 0.094μm.

 


HIT Ultrasonic Machining Technology Achievements


🕜 Efficiency - processing time of Threading reduced 83%
                           - processing time of Grinding reduced 60%
                           - processing time of the entire process reduced 58%
📈 Quality - (Threading) remained consistent
                           - (Grinding) surface roughness reduced from Ra > 0.8μm to the average of Ra < 0.1μm

⚙️ Tool Life remained stable
 
  HIT ultrasonic EDM
  Processing time of    threading < 60 minutes 360 minutes
  Processing time of    grinding < 4 hours 10 hours
  Processing time        (entire process) < 5 hours > 12 hours
  Surface roughness    (Ra) (average) 0.094μm -




 


Tungsten Carbide is widely applied in the Precision Machining industry, especially within sectors such as metal machining, metal forming tools, cutting tips, etc.


Due to its material properties of high hardness and rigidity, it is invaluable in making hardmetal, as well as making mill products, high-speed tools, military weapons, and other rugged applications.

Many of our clients specialize in Tungsten Carbide molds and punches machining.  They have encountered numerous difficulties in machining this material, and even tried out with other ultrasonic brands in the past.  However, the processing time was awfully long, and the tool life was not only short but unstable.

That was when they came to HIT's Ultrasonic Machining Module!  We offer a comprehensive solution in machining these difficult-to-cut materials.  With the assistance of our Ultrasonic Machining Technology, our clients stopped worrying about spending excessive amount of money on the tools due to unstable tool life.  The processing time can also be effectively reduced, resulting in a huge reduction in the production costs.  We can assure our clients of matching up with their requirements or even achieving  better outcome!