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Notes for further processing of nickel-based alloys


Notes for further processing of nickel-based alloys


The nickel base alloy material has high added value, its processing is also a quite difficult work.When encountering Inconel 600, 625, harnesey alloy C276 or B3 and other refractory alloy materials, machining knowledge and experience are very important.These materials have high strength, corrosion resistance and are subjected to extreme temperatures.Therefore, on the one hand, some special elements need to be added into the above materials to obtain superior performance;On the other hand, the addition of special elements makes the material particularly difficult to milling."Special steel 100 seconds" think, in the nickel series alloy occupies the dominant role in nickel and chromium two main components, in fact, in the processing of the opposite: increase in nickel can increase the toughness of the material, the addition of chromium can improve the hardness of the material, plus the balance of other components, tool wear is difficult to avoid.

Generally speaking, the other elements added to the material are silicon, manganese, molybdenum, tantalum, tungsten, etc. It is worth noting that tantalum and tungsten are also the main components used to make cemented carbide, which can effectively improve the performance of cemented carbide."Special steel 100 seconds" is colloquially similar to cutting another carbide tool with a carbide cutter.


Tool breakage and causes


Why cutting other materials milling cutter, planer tool head, in the processing of nickel base alloy damage faster?It's important to understand this.Machining nickel - based alloy, the tool cost is higher, the cost of milling ordinary steel 5-10 times.This point, small series in the end of the N06600 planer processing case will be Shared with users.


It goes without saying that heat is the most important factor affecting tool life when milling nickel base alloys.Extremely high cutting heat is not only a problem in milling nickel alloys.When milling nickel - based alloys, heat control is required.


Many tool damage is also related to other factors, unqualified jig and handle may shorten the tool life.When the workpiece clamped is not rigid enough, it may cause the fracture of cemented carbide matrix when it moves during cutting.Sometimes small cracks are created along the cutting edge, and sometimes a piece (commonly known as a chipping knife) breaks off the carbide blade, preventing further cutting.Accordingly, "special steel 100 seconds" remind below, before processing begins, try to strengthen the rigidity of jig, to the production of long time after can bring profit.It not only prolongs the tool life, but also improves the workpiece surface quality and reduces the machining error.


Of course, the blade may also be because the hard carbide or cutting load is too heavy.At this time, high speed steel cutting tools should be considered to reduce the occurrence of blade breakage.However, it should be noted that HSS cutters cannot withstand higher heat as hard alloys.Exactly what material to use, must weigh both according to the specific situation.

Likewise, improper selection of the handle can shorten the tool life.It is a principle to choose the handle as short as possible.These clamping requirements for cutters and workpieces are suitable for milling any material and, when milling nickel-based alloys, require as much advanced machining experience as possible.


Selection and use of cutting tools


No matter how well a tool is designed or what material it is made of, the expertise of the manufacturer of the tool is also an indispensable source of technology to help the economy of machining.


If the machining capacity of the cutter is exceeded, the cutter will be damaged.Insert milling is also the same, if the chip can not be timely from the bottom of the slot discharge, chip will be squeezed, after the tool will be damaged.In short, these conditions are detrimental to tool life when milling high temperature alloys.


It is also very important to choose proper cutting speed when milling nickel base alloy.It determines how much heat is generated in the cutting area.Recommended speeds range from the low 12 to 15m/min(for high speed steel cutters) to 23 to 37m/min(for carbide cutters) to 180 to 245m/min or higher (for ceramic cutters).Increasing feed and cutting depth also increases the cutting heat, which in turn increases the cutting force and the area of contact between the tool and the workpiece.


Influence of cutting heat and cooling heat dissipation


In milling nickel - based alloys, a large amount of cutting heat is produced.So in processing, the application of adequate coolant will be submerged cutting area, which is easy to achieve small diameter milling cutter, but for large diameter cutter (such as face milling cutter), cutting is not possible to be completely submerged, can only turn off the coolant, dry milling method.But for the planer, or can achieve online cooling when processing.


When the milling cutter can not be covered by coolant, heat on the blade quickly into, out, resulting in many perpendicular to the cutting edge of the very small crack, crack gradually expand, will eventually cause hard alloy fracture.


As mentioned above, the two main elements of nickel-based alloys are nickel and chromium.When metal smelters adjust the percentage content of each metal, its corrosion resistance, strength, hardness and other characteristics will change, as will its machinability and processing parameters.


It should be noted that it is not difficult to design tools that cut only tough or hard workpieces, but it is not easy to design nickel-based alloy tools that cut both.You may have a name for these alloys, but if you know their composition and use the right tool, you can easily mill materials like Haynes242, hastelloy C276, b-3, and so on.