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Tool Materials in Lathe Tool Production - Comparison
Lathe tools and turning inserts are fundamental cutting tools used in CNC machine tools. The precision, efficiency, and durability of the entire production process depend on their quality and proper matching to the type of machining. In this article, we discuss in detail the most commonly used tool materials, their properties, applications, and the benefits they offer in different working conditions.
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Cemented Carbides - The Basis of Modern Cutting Tools
Cemented carbides are the most commonly used material in the production of lathe tools and turning inserts. They are made by sintering hard particles, such as tungsten carbide, with a metallic binder, most often cobalt. Properties and advantages:
- High hardness and wear resistance, resulting in longer tool life.
- Resistance to high temperatures, making them suitable for machining at high cutting speeds.
- Versatility - they can be used for machining steel, cast iron, aluminum alloys, and other materials.
Application: Cemented carbides dominate external and internal turning, where high speeds and precision are required. They are especially popular in indexable turning inserts, which enable quick tool changes in CNC machine tools.
Technical Ceramics - Precision CNC Tools for Difficult Tasks
Technical ceramics are a tool material used in conditions where standard cemented carbide lathe tools reach their limits. They are made from oxides (e.g. Al2O3), nitrides, or carbides, offering exceptional wear resistance. Properties and advantages:
- Exceptional resistance to high temperatures allows machining without using lathe coolant.
- Good chemical stability minimizes the risk of reactions with the machined material.
Application: Ceramics are used for finish machining hardened steels and cast iron. Due to their brittleness, they work mainly in stable operating conditions without high dynamic loads.
CBN - The Specialist for Hard Materials
CBN (cubic boron nitride) is a tool material that has revolutionized the machining of hard materials. Its properties make it an ideal choice for cutting tools used in difficult conditions. Properties and advantages:
- Exceptional hardness, comparable to diamond, allows machining of hardened steels, white cast iron, and other difficult-to-machine materials.
- Thermal stability makes CBN perfectly suited for work at high temperatures.
Application: CBN lathe tools are indispensable in the production of precision components, such as shafts or machine parts requiring exceptionally high finish quality.
PCD - Diamond Cutting Tools
PCD (polycrystalline diamond) is one of the hardest materials used in turning inserts and lathe tools. Its properties make it indispensable in the machining of non-ferrous metals and abrasive materials. Properties and advantages:
- Unmatched wear resistance.
- Exceptional cutting precision, allowing very smooth surfaces to be achieved.
Application: PCD is an ideal choice for machining aluminum, copper, composites, and non-metallic materials such as wood and plastics.
High-Speed Steel - A Traditional Solution with Versatile Capabilities
High-speed steel (HSS) was the basic tool material before the introduction of cemented carbides. Although its importance has decreased, it is still used in specific applications. Properties and advantages:
- Flexibility and resistance to cracking allow use in less demanding conditions.
- Ease of sharpening and lathe tool reconditioning makes it cost-effective in small-batch production.
Application: HSS lathe tools are used for threading, grooving, and machining parts where lower cutting speeds are required.
How to Choose the Right Tool Material?
The selection of the tool material from which lathe tools and turning inserts are made depends on many factors:
- Type of machined material: For example, CBN may be suitable for hardened steel, while PCD may be suitable for aluminum.
- Working conditions: For high cutting speeds and high temperatures, cemented carbides or ceramics are a good choice.
- Part complexity and required precision: A high-quality finish can be achieved by using PCD or CBN cutting tools.
Summary
Lathe tools and turning inserts are an essential element of CNC machining, and their effectiveness depends on the tool material used. Cemented carbides offer a universal solution, ceramics and CBN provide excellent performance when machining hard materials, and PCD is indispensable for non-ferrous metals. Proper selection of cutting tools can significantly increase production efficiency and reduce operating costs.
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