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Hexagonal inserts for tooling come in various types. Each type is designed for specific applications and offers various benefits. Here is, however, a breakdown of the most common types.
Tungsten carbide inserts
Tungsten carbide hex inserts are the most common type of material used in making metalworking tool inserts. These types of inserts are durable and hardening. Moreover, they have excellent wear resistance. They make the ideal option for turning, milling, and drilling operations.
Cobalt-based inserts
In most cases, cobalt is combined with tungsten carbide to produce cobalt-based inserts. These inserts are tough and wear-resistant. Therefore, they are ideal for heavy-duty machining operations. They can withstand high temperatures and provide exceptional durability.
Ceramic inserts
Ceramic hexagonal inserts are typically used for high-speed machining operations. They offer excellent wear resistance. They also come with an ability to withstand extreme temperatures. Typically, these inserts are suitable for finishing operations on hardened materials.
CBN inserts
Cubic boron nitride (CBN) inserts are used for machining ferrous materials. They possess high thermal stability and wear resistance. This makes them ideal for precision machining. Normally, they are commonly used in grinding operations as well as turning cast iron, steel, and other alloys.
PCD inserts
Polycrystalline diamond (PCD) inserts come with unmatched wear resistance and are exceptionally tough. They are normally used for machining non-ferrous metals. Some of these metals include aluminium, copper, and magnesium. They are also suitable for producing components with tight tolerances. This is because these hexagonal inserts usually extend the insert’s life in addition to reducing the need for frequent tool changes.
Steel inserts
Hexagonal steel inserts are the most commonly used type of ceramic tool inserts for metalworking applications. They are widely cherished for their strength, toughness, and affordability. They are usually used in applications with lower cutting speeds and less abrasive materials.
When selecting turning tool inserts there are several factors a buyer needs to consider. This will ensure optimal performance and longevity during machining operations, after all, the right insert will make all the difference. Here are some of those key factors.
Material compatibility
Inserts are normally designed to work well with specific materials. For instance, tungsten carbide inserts are ideal for general-purpose machining of steel, aluminium, and other metals. On the other hand, PCD and CBN inserts are specifically designed for non-ferrous and ferrous materials respectively. Always ensure the chosen insert material is compatible with the customer’s workpiece material to avoid wear excessive wear or damage.
Pressure
Generally, pressure is a paramount consideration when selecting hexagonal inserts. Typically, higher pressure will be required when machining harder materials. However, softer materials can do with lower pressure. So, choose an insert that can accommodate both the pressure required and the material being worked on.
Cutting edge geometry
The cutting edge geometry of an insert also impacts the insert’s performance. For instance, inserts with sharp cutting edges are ideal for finish machining. They offer smooth surfaces and tight tolerances. On the other hand, those with robust geometries are well-suited for roughing. They help in material removal at a faster rate. Depending on the customer’s machining needs, choose an insert that will best suit their needs.
Insert size and shape
Choosing the right insert size and shape is imperative for achieving optimal results. Generally, larger inserts are better suited for heavy-duty machining. Meanwhile, smaller ones are ideal for intricate work. Furthermore, make sure to match the insert size with the customer’s tool holder to ensure proper fitment.
Land type
The land type refers to the finishing edge of the insert, which supports the cutting edge. There are generally two types of land types. These are the flat land and the radius land type. The flat land type is ideal for finish cutting. Conversely, the radius type is ideal for general cutting. When selecting an insert, ensure to choose one that will suit the customer’s intended application.
Tolerance
Tolerances are normally crucial in precision machining. This is because they affect the final product’s dimensions. Inserts with tight tolerances usually offer higher precision. On the other hand, those with looser tolerances are usually more forgiving and suitable for less stringent requirements. Consider the customer’s tolerance requirements when choosing hexagonal inserts for machining operations.
How buyers maintain these inserts affects their performance and longevity. In addition, these machining inserts come with several specifications that buyers must take note of. Here is a breakdown of those key maintenance and specification considerations.
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These inserts are normally made from various materials. The most notable are tungsten carbide, cermet, ceramic, PCD, and CBN. These materials have varying degrees of hardness, toughness, and wear resistance. So, the choice of material used in the insert will depend on the customer’s machining needs and material.
Insert geometry
Usually, the geometry of the hexagonal inserts has a notable impact on the cutting action. For instance, the rake angle affects the material removal rate. On the other hand, the clearance angle impacts the surface finish of the material being machined. More importantly, different machining operations normally require different geometries. For example, turning, milling, and drilling inserts have distinct geometries.
Insert size
The size of the insert will determine the type of tool holder it will fit into. Generally, these inserts come in standard sizes. However, custom sizes are usually available for specific applications. Note that size compatibility will ensure proper tool alignment and achieve optimal cutting performance.
Coating
Frequently, machine tool inserts come with coatings that improve the insert’s performance. Common coatings include TiN (Titanium Nitride), TiAlN (Titanium Aluminium Nitride), and CrN (Chromium Nitride). These coatings improve the insert’s thermal resistance, reduce friction, and enhance wear resistance. This significantly prolongs the insert’s useful life.
Proper maintenance of hexagonal inserts is a must. Not only does it improve the tool’s performance, but it also increases its lifespan.
Regular inspection
Conducting regular inspections of the inserts as well as the machine’s parts will help detect any signs of wear or damage. Usually, early detection of worn-out parts will prevent further damage and also give room for necessary replacements.
Proper cleaning
Cleaning these hexagonal inserts after every use will help prevent the buildup of debris or residue. This residue will affect the performance of the inserts. In addition, this residue can cause premature wear. Use appropriate cleaning agents that don’t damage the inserts to clean them. Cleaning them will also give room for inspection.
Correct tool setup
The way buyers set up these tools significantly impacts their performance and longevity. That’s why it is imperative to ensure proper alignment in order to achieve balanced wear.
Avoiding excessive wear
Avoiding excessive wear means avoiding overuse. More importantly, change the inserts when the visible signs of wearing are evident. Overused inserts will affect the quality of machining and, in effect, will cause damage to the machine parts.
Hexagonal inserts are a versatile and practical tool to have. They are mainly used for various turning, milling, and drilling operations in different machining applications. Below are common scenarios where these tool holders perform optimally.
Precision machining of small parts
Hexagonal inserts are typically used in precision machining to create tightly toleranced features and smooth surface finishes. Their ability to make accurate cuts makes them ideal for small, intricate parts commonly found in the electronics, medical devices, and aerospace industries. Additionally, these inserts’ geometry and material allow them to maintain sharp edges. This ensures consistent quality throughout the machining process.
Automotive component manufacturing
In the automotive industry, these tool inserts are normally used for machining critical components such as engine parts, transmission components, and shafts. They also machine finishes or key wear surfaces that need to support cutting edges. They are also used for creating gears, which require strong and durable cutting tools. That’s why auto manufacturers prefer these inserts due to their ability to withstand high abrasion and stress. More importantly, they offer better fuel economy and improved performance because they are lightweight.
Metal cutting for construction
These hexagonal inserts are suitable for metal cutting in the construction industry. Particularly, they are used to drill and mill materials such as steel and aluminium. Because of their durability and strength, they make quick and effective cuts. More importantly, they can be used on various machines, making them versatile.
Woodworking
In the woodworking industry, hexagonal inserts are generally used for planing, shaping, and grooving wooden pieces. Their sharp edges and ability to chip-resistant make them ideal for creating smooth finishes on various wood types. They are widely used for trimming and making dado cuts. Besides, their quick replacement and re-sharpening capability make them a practical choice for maintaining consistent cutting performance on professional-grade equipment.
Holes and cavity creation on plastics
These economically affordable hexagonal inserts are also suitable for CNC milling in the production of plastic parts. Their material and geometry provide smooth cutting action with minimal heat buildup. Therefore, they are ideal for machining cavities, holes, and complex shapes in various plastic substrates.
A1. The most common material for making these inserts is tungsten carbide. It is also commonly referred to as carbide. This material is widely popular because of its toughness and hardness. It also has stellar wear resistance. There are also other types of materials used to make these inserts. They include cermet, ceramic, CBN, and PCD. Each of these materials has its own advantages. For instance, PCD and CBN have unmatched precision and long life for non-ferrous and ferrous materials respectively.
A2. Yes, these insert tools are material-specific job aids. This is because the type of insert used significantly influences the machining performance. Aluminum, for instance, generally requires inserts with lower toughness. On the other hand, steel requires high hardness and wear resistance.
A3. The primary role of a coating on hexagonal is to improve the insert’s performance and extend its life. Coatings like TiN and TiAlN provide better thermal resistance, reduced friction, and increased wear resistance. They prolong tool life. Another advantage of coatings is that they provide insert adaptability. In situations where there are new machining requirements, manufacturers can change the insert coating instead of changing the insert entirely. This will save on costs and will be more efficient.
A4. Several indicators can show when to replace these inserts. Some of them are visible wear, chipping, and signs of corrosion. Moreover, machining performance will also drop, causing poor surface finishes and inaccurate dimensions. Inserts can also be checked for wear after operating at intervals. This enables inserts that are worn out to be replaced in a timely manner. Replacing worn-out inserts improves productivity, increases efficiency, and guarantees product quality.
A5. Yes, they can. This is one of the major advantages of these hexagonal inserts. They can easily be sharpened instead of being replaced when they wear out. Sharpening also elongates insert life, thus making it economical in the long run. However, it should be noted that not all types of inserts are easily sharpened. For instance, PCD and CBN inserts come with extraordinary hardness and are often not sharpened. More often than not, they are replaced entirely.
