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Kennametal insert grades are of different types and are used for various functions in the industry. Thus, understanding the diverse qualities preferred for certain machining applications will help one make informed decisions when selecting inserts. The most common types include:
Cemented carbide inserts offer great hardness and wear resistance, making them suitable for cutting tools. In addition, they withstand high temperatures without losing their cutting edge, which is useful in critical machining operations. Most importantly, Kennametal's cemented carbide inserts are commonly used in turning, milling, and drilling operations in various materials ranging from steel to nickel alloys, which are ideal for general engineering.
Ceramic inserts are made from aluminum oxide or silicon nitride. These inserts are harder than carbide but less tough, often used for machining hard materials. Most importantly, they retain their sharp edge for a long time, which makes them ideal for high-accuracy applications. Also, they are more fragile and hence should be applied in processes whereby the workpiece rotation speed is consistent.
HSS inserts are made from iron alloyed with tungsten and molybdenum. They are tough and work well at steel cutting tool temperatures, making them ideal for machining processes without effective coolant. In addition, while not as wear-resistant as cemented carbide or ceramic inserts, they are durable in interrupted cuts or when machining materials that are relatively easy to machine.
Cubic boron nitride inserts are among the hardest materials available after diamond. Usually, they are preferred for grinding operations and machining hard-to-cut materials, such as hardened steel. Also, they provide excellent wear resistance and retain their sharpness for long periods, making them valuable in precision machining.
PCD inserts are made from synthetic diamond particles sintered under high pressure and temperature. Usually, they provide outstanding wear resistance and are suitable for machining nonferrous materials. Commonly, they are used in industries for cutting aluminum, copper, and composites, which are ideal for their smooth finish and high productivity.
Kennametal insert grades are manufactured to provide enhanced durability in different machining applications. Also, their advanced materials and innovative technology ensure they withstand critical cutting conditions. Hence, this minimizes wear and maintains performance.
As mentioned, wear resistance is a key feature of Kennametal inserts. They are designed to cope with normal wear, which is the gradual erosion of the cutting edge due to friction with the work material. Also, they feature special grades for high-wear conditions that incorporate hard, fine-grained carbide substrates. These substrates prolong the edge life by hardening the material beneath the cutting edge, which makes it less susceptible to wear.
Impact resistance is also notable. Generally, it is especially crucial in interrupted cuts or when machining brittle materials. For instance, PCD or CBN, which are high-hardness materials, have enough toughness to resist the chipping and fracture that could result in such conditions. Moreover, some Kennedy-metal carbide inserts are shock-resistant, particularly designed to absorb impact forces effectively.
Temperature resistance is another vital aspect. Machining operations can generate excess heat, which could result in insert grade softening, edge wear, or even thermal cracking. Luckily, Kennametal's cemented carbide grades are formulated to withstand these elevated temperatures without losing hardness. This maintains their cutting ability even under extreme conditions like steel turning.
Kennametal insert grades are usually made from diverse materials, each selected for its suitable properties based on the intended application. Commonly, these materials range from tough and durable cemented carbide to robust tungsten.
Cemented carbide is the most prevalent material for these inserts due to its exceptional hardness, wear resistance, and ability to resist high temperatures. Commonly, it is made from tungsten carbide particles that are binded together in a metallic cobalt matrix. The result is a tough, durable material that holds the cutting edge for long periods. Additionally, this grade is ideal for general machining operations, which include turning and milling.
For extreme conditions, CBN inserts are preferred, which are the second hardest material after natural diamond. Also, CBN is produced by chemically altering nitrogen atoms bonded to a carbon atom in a cubic strong structure. Typically, it is particularly suited for grinding hardened steel or super alloys. Moreover, CBN's heat resistance property reduces wear during high-temperature machining, making it valuable for precision cutting. In addition, its hardness guarantees it cuts robust materials while retaining sharpness for longer than softer inserts.
Aluminum oxide is mainly the source of ceramic inserts. Also, they are known for their exceptional wear resistance and undoing heat properties, which makes them highly suitable for such tough but brittle materials as steel. Even though they are more brittle than other inserts, ideally suited for finishing operations because of their ability to give a smooth finish and high-level precision. Mostly, they come in handy in the event finishes and tolerances are of high priority.
Usually, Kennametal inserts are ideal for various machining scenarios, making them a versatile choice regarding precise cutting operations. In addition, these scenarios include turning, milling, drilling, and other critical operations across multiple industries.
In turning operations, cutting inserts perform the primary function of removing material from a rotating workpiece. Specifically, they shape and refine pieces like shafts and cylinders made of steel alloys and aluminum.
In this case, Kennametal's cemented carbide inserts are suitable for these turning tasks due to their exceptional wear resistance and ability to endure high temperatures. Normally, they retain their cutting edge for extended periods. Also, they minimize wear when cutting such tough work materials as steel alloys. This makes them ideal for turning components used in the aerospace and automotive industries.
Mostly, in milling operations, Kennametal inserts are also favored, especially in industrial manufacturing. Typically, face milling inserts are applied to remove material from the surface of a workpiece, creating smooth, flat surfaces. In these operations, PCD, CBN, and cemented carbide inserts excel handling hard materials like titanium and hardened steel. These materials are often encountered in defense, aerospace, and tool-and-die making.
Ideally, in drilling operations, insert grades, especially cemented carbide ones, are well-suited for creating precise holes in various materials. In addition, these inserts efficiently cut through metals, offering durability and prolonging the tool's lifespan.
Also, Kennametal tools and inserts are popularly used in rock drilling across mining and construction industries. For example, cemented carbide inserts are designed to withstand the abrasive nature of hard rock. They also ensure efficient penetration while minimizing wear, which ultimately leads to improved productivity in challenging drilling conditions.
These inserts cut narrow slots or grooves in engineered materials, including complex composites. Ideally, their sharp edges and robust materials enable them to maintain precision in this delicate work. Moreover, they prevent chipping and excessive wear. This simply makes them perfect for this operation.
When selecting these insert grades, one should consider their mechanical properties, which affect their performance in this practice. Henceforth, these properties include hardness, toughness, grade, and geometry, which are essential to focus on.
As for hardness, high-hardness grades possess excellent wear resistance property. Thus, they retain their cutting edge for extended periods. This makes them ideal for high-volume production. On the other hand, low-hardness grades are relatively easier to manufacture. Moreover, they are suitable for low-volume production where insert changeovers can be done often.
When talking about toughness, tough grades can absorb shocks without chipping or breaking. This property makes them suitable for interrupted cuts or when machining uneven work materials. Less tough grades are suitable for light cutting operations, which experience fewer shocks.
Also, the cutting edge plays a vital role. Ideally, they come in diverse shapes. Each shape is designed for specific applications. For instance, round inserts provide superior wear resistance when performing finishing operations. Flat inserts are most effective in heavy cutting operations as they have broader contact with the work material.
The grade is usually refined by layering hard materials like titanium carbo-nitride and cobalt. This generally enhances the insert's wear resistance and toughness properties. One should understand that finer grades are preferred for hard steels, strongly opposing tougher grades for unstable materials. Generally, complex materials benefit from multilayered inserts that incorporate diverse carbide grades.
Q1. Regularly removing cutting particles using an air blower or brush helps in maintaining these tools. Besides, they must be kept in a dry area when not in use to prevent moisture accumulation. Often, these tools are stored in protective cases. This protects them from physical damage and avoids accidental cutting.
A2. These grades are normally composed of diverse materials, each suited to particular machining demands. Usually, tough cemented carbide is the material predominantly used. This is due to its exceptional hardness and wear resistance property, which makes it suitable for high-performance cutting tasks.
Q3. Inserts are fabricated to perform and stay durable under adverse machining conditions. Either extreme temperatures or high-pressure environments. Different materials, such as high-speed steel and cubic boron nitride, are able to endure significant heat without deforming or losing their cutting edge. This makes them ideal for such precision work.
Q4. The properties to look out for include insert grade toughness, which enables them to withstand impact without chipping or breaking. Also, advanced wear resistance retains cutting edge over time. Moreover, thermal resistance ensures these inserts do not deform at high temperatures. Ultimately, high brittleness prevents insert breaking during operation.
Q5. Mostly, aerospace and automotive industries derive great value from these inserts in their machining processes. In these industries, precision, durability, and superior-quality finish are crucial. Also, these inserts provide exceptional wear resistance and maintain sharpness, which leads to efficient machining of difficult materials.
