Machine tooling comes in many types and configurations including fixtures, jigs, and cutting or material removal tools. They are all subject to wear over time, and cutting tools in particular can become dull and out of tolerance after many cycles. This is especially the case in high-volume production and when hard materials are being cut repeatedly.
Hardened steel is often used to manufacture these cutting tools; however, tungsten carbide is a durable and cost effective alternative. Keep reading to learn more about how solid carbide can be used to make tooling and some of the advantages of this material.
What Is Solid Carbide Tooling?
Tungsten carbide tooling can be manufactured efficiently through the process of powder metallurgy. A blend of powderized metals, including tungsten carbide and others, along with lubricants and binders, are packed into a mold, then compressed to hold the shape. The molded piece, also called a “green compact,” is removed from the mold and placed in a sintering furnace for a predetermined period of time at a temperature just below the material’s melting point. Sintering makes the compacted form permanent, solid, and extremely strong for cutting and material removal tasks.
Improved Service Life and Durability
While all tooling wears down or breaks eventually, extending its lifespan can save time and money in the long run. Carbide tooling is much longer-lasting and more durable than HSS/cobalt tooling because it has increased hardness and wear resistance. As a result, the same tooling can be used for more production cycles without replacement or unplanned downtime for repairs.
Enhanced Cutting Performance
Because solid carbide is hard and tough, it holds a cutting edge for longer without blunting or deforming, even in high-speed CNC machines. Because the cutting edges remain true for longer, the cuts they make are more accurate and stay in tolerance. This further reduces scrap, waste, and time spent remaking parts.
The hardness of sintered tungsten carbide also makes the tooling compatible with a greater range of materials that other tools can’t handle as well or at all, such as hardened steel, stainless steel, titanium, and high-temp alloys.
Increased Heat Resistance
High-speed machining generates high heat due to friction, which carbide tooling can resist without deforming or deteriorating. This is because solid carbide can disperse heat uniformly and quickly throughout its structure, which reduces any build up of damaging heat in a single area. By utilizing different additives, such as tantalum carbide within the tungsten carbide matrix, even further resistance to heat can be achieved.
Reduced Tool Deflection
Solid carbide’s strength minimizes the risk of deflection and push-off forces damaging workpieces at the end of each cutting stroke. The tools remain rigid and leave behind crisp edges, for consistent high quality. Solid carbide tooling also resists vibration than tooling made with other materials, which contributes to precise cuts and higher-quality finishes.
Cost-Effectiveness of Solid Carbide Tooling
Solid carbide tooling is a long-term investment that provides cost savings over time. Some reasons for this include:
- Fewer replacement orders for standard and custom tooling.
- Less downtime and disruption to workflow.
- Lower repair and maintenance costs.
- Greater overall efficiency.
- Fewer product discards due to errors and deformation.
Solid Carbide Program From Ultra-Met
Ultra-Met specializes in powder metallurgy with solid carbide blends for tooling and other forms used in many industrial applications. We serve the manufacturing, aerospace, energy, automotive, medical, and metalworking industries with custom and standard tooling. Contact us today to learn more about our services or request a quote to start your order.